OWNER'S MANUAL 2008
690 ENDURO EU
690 ENDURO AUS/UK
ART. NO. 3211239en
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DEAR KTM CUSTOMER
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 great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Dealer's stamp
The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small
deviations arising from further development in design and construction.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of delivery.
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DEAR KTM CUSTOMER
2
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
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.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
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CONTENTS
3
CONTENTS
GENERAL TIPS AND HINTS ON PUTTING INTO
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CONTENTS
4
Important maintenance work to be carried out by an
Important maintenance work to be carried out by an
Adjusting the low-speed compression damping of the shock
Adjusting high-speed compression damping of the shock
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CONTENTS
5
Changinxg engine oil and oil filter, cleaning oil
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CONTENTS
6
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MEANS OF REPRESENTATION
7
1MEANS OF REPRESENTATION
Symbols used
The symbols used are explained in the following.
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 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.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Eigenname
Indicates a proprietary name.
Name®
Identifies a protected name.
Marke™
Identifies a brand in merchandise traffic.
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IMPORTANT NOTES
8
2IMPORTANT NOTES
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.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
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IMPORTANT NOTES
9
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop.
KTM accepts no liability for other products and any resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Transport
Note
Danger of damageꢀDanger of damage by the vehicle running away or falling over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazardꢀSome components (engine, radiator and exhaust system) get very hot when the engine is running.
–
Do not place the vehicle where there are flammable or explosive substances.
–
–
Switch off the engine and remove the ignition key.
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential
problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that
such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.
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IMPORTANT NOTES
10
Notes/warning notes
Pay attention to the specified notes and warnings.
Info
Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing, you or
others may not recognize dangers and may therefore be injured.
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Caution
Danger that could possibly lead to slight injuries.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
OWNER'S MANUAL
–
Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you
operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you
can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
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IMPORTANT NOTES
11
–
The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
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VIEW OF VEHICLE
13
1
Hand brake lever
Clutch lever
Handrail
2
3
4
Filler cap
5
Seat
6
Front brake caliper
Shift lever
7
8
Engine number
Side stand
9
10
11
Footrest
Seat release strap
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VIEW OF VEHICLE
15
1
Ignition/steering lock
2
Rear mirror
3
Light switch, flasher switch, horn
Combination instrument
Emergency OFF switch, electric starter button
Throttle grip
4
5
6
7
Chassis number
8
Rear brake caliper
9
Passenger footrest
10
11
12
Shock absorber rebound damping
Foot brake pedal
Engine oil level viewer
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LOCATION OF SERIAL NUMBERS
16
4LOCATION OF SERIAL NUMBERS
4
Chassis number
.1
The chassis number is stamped on the steering head on the right.
100217-10
4
.2
Type label is located on the upper right frame tube below the seat.
100218-10
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LOCATION OF SERIAL NUMBERS
17
4
.3
ey 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
4
.4
ngine number
The engine number is stamped on the left side of the engine under the engine sprocket.
100211-10
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LOCATION OF SERIAL NUMBERS
18
4
.5
ork part number
The fork part number is stamped on the inner side of the fork stub.
100214-10
4
.6
hock absorber part number
Shock absorber part number can be viewed from the right side.
100216-10
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OPERATING ELEMENTS
19
5OPERATING ELEMENTS
5
C
.1
lutch lever
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
100219-10
5
.2
and brake lever
The hand break lever is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.
100220-10
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OPERATING ELEMENTS
20
5
.3
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.
500020-01
5
.4
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.
100222-10
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OPERATING ELEMENTS
21
5
.5
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)
is actuated.
500020-11
5
.6
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. The flasher
switch returns automatically to the central position after use.
To switch off the flasher light, press the flasher switch towards the switch case.
500021-10
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OPERATING ELEMENTS
22
5
.7
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. The flasher
switch returns automatically to the central position after use.
To switch off the flasher light, press the flasher switch towards the switch case.
100223-10
5
.8
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.
500021-11
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OPERATING ELEMENTS
23
5
.9
orn
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.
100224-10
5
.10
mergency OFF switch
The emergency OFF switch is fitted on the left 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 operation as the
ignition circuit is closed.
100225-10
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OPERATING ELEMENTS
24
5
.11
The electric starter button is fitted on the right side of the handlebar.
Possible states
•
•
Electric starter button in basic position
Electric starter button pressed – In this position, the electric starter is actuated.
100226-10
5
.12
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 circuit is closed, and the engine
can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
steering locked. The ignition key can be removed.
100221-10
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OPERATING ELEMENTS
25
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
5
.14
ombination instrument - function buttons
Press the MODE button to change the display mode.
Possible display modes are total distance covered (ODO), tripmaster 1 (TRIP 1) and tripmas-
ter 2 (TRIP 2).
Press the SET button to reset tripmaster 1 (TRIP 1) and tripmaster 2 (TRIP 2) to 0.0.
Button has no function.
700117-01
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OPERATING ELEMENTS
26
5
.15
ombination instrument - tachometer
The tachometer displays the engine speed in revolutions per minute.
The red marking shows the excess engine speed range.
100118-10
5
.16
ombination instrument - control lamps
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
on.
Idling speed indicator lamp lights up green – Transmission is in neutral.
High beam indicator lamp lights up blue – High beam is switched on.
Temperature warning lamp lights up red – Coolant has reached a critical
value.
100119-10
Fuel level warning lamp lights up orange – Fuel level has reached the reserve
mark. Display switches to TRIP F.
FI warning lamp (MIL) lights/flashes orange – The OBD has detected an
emission- or safety-critical error.
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OPERATING ELEMENTS
27
Battery warning lamp lights up – Voltage in electrical system too low.
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.
Info
2205 mm equals the circumference of the 21" front wheel with a series production
tire.
The display then changes to the last selected mode.
400404-01
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OPERATING ELEMENTS
28
5
.18
ombination instrument - speed display
The speed is displayed in kilometers per hour km/h or miles per hour Mph.
700114-01
5
.19
etting kilometers or miles
Info
If you change the unit, the ODO value is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is standing.
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OPERATING ELEMENTS
29
–
–
–
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
Activation duration of MODE button
10 s
700120-01
5
.20
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
5
.21
Condition
The motorcycle is standing.
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OPERATING ELEMENTS
30
–
–
–
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.
The time is set.
700115-10
5
.22
ombination 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
5
.23
ombination 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.
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OPERATING ELEMENTS
31
–
–
–
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
5
.24
Info
The tripmaster TRIP 2 operates constantly and counts up to 999.9.
You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins
again at 0.0.
–
–
–
Switch on the ignition by turning the ignition key in the position
.
Press the MODE button several times until the TRIP 2 display mode is active.
Keep the SET button pressed.
The TRIP 2 display is at 0.0.
700122-01
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OPERATING ELEMENTS
32
5
.25
ombination instrument - TRIP F display
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
5
.26
The temperature indicator in the display consists of 12 bars. The more bars that light up,
the hotter the coolant. When the top bar lights up, all bars begin to flash simultaneously
and the temperature warning lamp begins to light up.
Possible states
•
•
•
Engine cold – up to four bars light up.
Engine at normal operating temperature – from five to eleven bars light up.
Engine hot – all twelve bars flash.
700124-01
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OPERATING ELEMENTS
33
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
5
.28
–
–
Put the filler cap back on and turn the ignition key 90° clockwise.
Remove the ignition key and fold down the cover.
100228-01
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OPERATING ELEMENTS
34
5
.29
andrails
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
5
.30
eat release
The seat can be released using strap .
100230-10
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OPERATING ELEMENTS
35
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.
100231-01
5
.32
The shift lever is mounted on the left side of the engine.
100215-10
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OPERATING ELEMENTS
36
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
100212-10
5
.33
The footbrake pedal is located in front of the right footrest.
The footbrake pedal operates the rear brake.
100232-10
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OPERATING ELEMENTS
37
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
electric starter system is active.
•
Side stand folded in – This position is mandatory for all journeys. The safety electric
starter system is inactive.
100233-10
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
38
6GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
6
.1
dvice on first use
Danger
Danger of accidentsꢀDanger from inadequate traffic experience.
–
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injuryꢀRisk of injury by missing/inadequate protective clothing.
–
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle. Always
wear protective clothing, which must be in perfect condition and meet legal requirements.
Warning
Danger of crashingꢀImpairment of riding behavior due to different tire tread patterns on front and rear wheels.
–
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidentsꢀUncontrollable handling behavior caused by non-approved tires/wheels.
–
Use only tires/wheels approved by KTM with the corresponding speed index.
Warning
Danger of accidentsꢀReduced road grip with new tires.
–
New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in
the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle
has been run in.
Warning
Danger of accidentsꢀBrake 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.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
39
Info
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.
Before your first trip, read the entire operating instructions carefully.
Get to know the operating elements.
–
–
–
–
–
–
Adjust the basic position of the foot brake pedal.
x
Get used to handling the vehicle on a car park before making a longer trip. Try also to ride as slowly as possible and in a standing posi-
tion to get a better feeling for the vehicle.
–
–
–
Do not make any offroad trips that over-stress your ability and experience.
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
Do not make any changes to the vehicle, and use only KTM approved parts.
Info
Parts from other manufacturers can reduce the operational safety of the vehicle.
–
Run the engine in.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
40
6
.2
unning in the engine
–
During the running-in phase, do not exceed the specified engine speed and engine performance.
Specification
Maximum engine speed
During the first: 1,000 km (621.4 mi)
After the first: 1,000 km (621.4 mi)
6,000 rpm
7,800 rpm
–
Avoid fully opening the throttle!
6
.3
oading the vehicle
Warning
Danger of accidentsꢀUnstable riding behavior.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidentsꢀUnstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
–
Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidentsꢀUnstable handling characteristics at high speed.
–
Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage.
Maximum speed with baggage 130 km/h (80.8 mph)
Warning
Danger of accidentsꢀRisk of breakage of suitcase system.
–
If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
41
Warning
Danger of accidentsꢀPoor visibility for other road users due to slipped baggage.
–
If the tail light is covered, you are less visible to following traffic, especially in the dark. Check the way your baggage is fixed
regularly.
Warning
Danger of accidentsꢀChanged handling characteristics and longer stopping distance with excessive payload.
–
Adapt your speed according to your payload.
Warning
Danger of accidentsꢀUnstable handling characteristics due to slipped baggage.
–
Check the way your baggage is fixed regularly.
Warning
Danger of burnsꢀA 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.
–
–
If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu-
tion between the front and rear wheels.
Do not exceed the overall maximum permitted weight and the axle loads.
Specification
Maximum permissible overall weight
Maximum permissible front axle load
Maximum permissible rear axle load
350 kg (772 lb.)
150 kg (331 lb.)
200 kg (441 lb.)
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RIDING INSTRUCTIONS
42
7RIDING INSTRUCTIONS
7
.1
hecks 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.
–
–
–
–
Check the engine for loss of oil.
Check the fuel level.
Specification
all
1,000 km (621.4 mi)
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Check brake system function.
Check that all operating elements are correctly adjusted and free to move.
Check the functioning of the electrical equipment.
Check that baggage is correctly secured.
Sit on the motorcycle and check the rear mirror setting.
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RIDING INSTRUCTIONS
43
7
.2
Danger
Danger of poisoningꢀExhaust 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 accidentsꢀIf the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–
Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failureꢀHigh engine speeds in cold engines have a negative effect on the service life of the engine.
–
Always warm up the engine at low engine speeds.
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RIDING INSTRUCTIONS
44
–
–
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. At the same time, the combination instrument runs a function test.
–
–
Shift gear to neutral.
The green idling speed indicator lamp N lights up.
Press the electric starter button
.
Info
Do not press the electric starter button until the combination instrument func-
tion test is finished.
Do not open the throttle when starting. If you open the throttle when starting,
the engine management injects no fuel and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds until
trying again.
This motorcycle is equipped with a safety electric starter system. The engine
can be started only if the gearbox is in neutral or the clutch lever is pulled. If
you shift into gear when the side stand is folded out and then release the clutch
lever, the engine stalls.
–
Take the weight off the side stand and swing it back up with your foot as far as it will
go.
100239-10
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RIDING INSTRUCTIONS
45
7
.3
tarting up
–
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
7
.4
hifting, riding
Warning
Danger of accidentsꢀAn abrupt load alterations can cause the vehicle to get out of control.
–
Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidentsꢀIf you change down at high engine speed, the rear wheel can lock up.
–
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
Warning
Danger of accidentsꢀMalfunctions caused by incorrect ignition key position.
–
Do not change the ignition key position during a journey.
Warning
Danger of accidentsꢀDistraction from traffic activity by adjustments to the vehicle.
–
Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injuryꢀThe passenger must be capable of sitting correctly on the passenger seat.
–
The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests. Note the regulations
governing the minimum age of passengers in your country.
Warning
Danger of accidentsꢀDanger of accidents caused by dangerous driving.
–
Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible.
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RIDING INSTRUCTIONS
46
Warning
Danger of accidentsꢀReduced 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 accidentsꢀReduced road grip with new tires.
–
New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in
the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle
has been run in.
Warning
Danger of accidentsꢀUnstable riding behavior.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidentsꢀUnstable handling characteristics due to slipped baggage.
–
Check the way your baggage is fixed regularly.
Warning
Danger of accidentsꢀAfter a fall, check the vehicle.
–
After a fall, check the vehicle as usual before putting it into operation.
Note
Engine failureꢀUnfiltered 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.
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RIDING INSTRUCTIONS
47
Note
Engine failureꢀOverheating 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 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.
Release the throttle while simultaneously pulling the clutch lever, shift into the next
gear, release the clutch and open the throttle.
Info
For the positions of the 6 forward gears, see the illustration. The neutral or idle
position is between the first and second gears. First gear is used for starting off
or for steep inclines.
The operating temperature is reached when 5 bars of the temperature indicator
light up.
100212-10
–
–
When you reach maximum speed after fully opening the throttle, turn back the throttle
to about ¾ of its range; the speed hardly drops, but the fuel consumption falls consid-
erably.
Open the throttle only as far as the road and weather conditions permit. Particularly in
bends, do not shift and open the throttle only very cautiously.
–
–
To shift down, brake if necessary and close the throttle at the same time.
Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open
the throttle or shift again.
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RIDING INSTRUCTIONS
48
–
For example, if the engine stalls at a junction, just pull the clutch and press the electric
starter button. You do not need 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 the cooling system.
–
–
Ride with a lower engine speed instead of with a high engine speed and a slipping
clutch.
If the FI warning lamp (MIL) starts to light up during the journey, stop immediately. If
you shift to neutral, the FI warning lamp (MIL) begins to flash.
Info
From the flash rhythm, you can deduce a two-digit number, the so-called flash
code. The flash code tells you which component is affected by a fault.
7
.5
Warning
Danger of accidentsꢀIf you brake too hard, the wheels can lock.
–
Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidentsꢀReduced braking due to wet or dirty brakes.
–
Clean or dry dirty or wet brakes by riding and braking gently.
Warning
Danger of accidentsꢀReduced 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.
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RIDING INSTRUCTIONS
49
Warning
Danger of accidentsꢀBrake 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 accidentsꢀLonger stopping distance due to higher overall weight.
–
Take the longer stopping distance into account when carrying a passenger and baggage.
Warning
Danger of accidentsꢀDelayed brake action on salted roads.
–
Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by brak-
ing.
–
–
–
–
To brake, release the throttle and operate the front and rear brakes simultaneously.
On sandy, wet or slippery surfaces, use the rear brake.
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In
this way, you have to brake far less and the brakes do not overheat.
7
.6
topping, parking
Warning
Risk of misappropriationꢀUsage by unauthorized persons.
–
Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the
vehicle, lock the steering and remove the ignition key.
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RIDING INSTRUCTIONS
50
Warning
Danger of burnsꢀSome 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 damageꢀDanger of damage by the vehicle running away or falling over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazardꢀSome components (engine, radiator and exhaust system) get very hot when the engine is running.
–
Do not place the vehicle where there are flammable or explosive substances.
Note
Material damageꢀDamage and destruction of components by excessive load.
–
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand
only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
–
–
–
Brake the motorcycle.
Shift gear to neutral.
Switch off the ignition by turning the ignition key in the position
.
Info
If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power
continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine
with the ignition key - the emergency OFF switch is intended for emergencies only.
–
–
Park the motorcycle on a hard surface.
Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.
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RIDING INSTRUCTIONS
51
–
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.
.
7
.7
efueling
Danger
Fire hazardꢀFuel can easily catch fire.
–
Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoningꢀFuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc-
tor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazardꢀImproper 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.
Info
This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel
only.
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RIDING INSTRUCTIONS
52
–
–
–
switch off engine.
Fill the fuel tank with fuel up to measurement .
Specification
Measurement of
20 mm (0.79 in)
Fuel tank content
12 l (3.2 US gal)
Super unleaded (ROZ 95 / RON 95 /
400405-10
–
–
Press the SET function button for 2 seconds.
The fuel level warning lamp switches off. TRIP F is set to 0 and appears in the
previous display mode.
Info
If you do not press the SET function button, the reset takes place automati-
cally after about 3 minutes.
100240-10
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GREASING AND SERVICE TABLE
53
8GREASING AND SERVICE TABLE
8
Important maintenance work to be carried out by an authorized KTM workshop.
.1
K10N
K50A
K100A
J1A
J2A
•
Engine
•
•
•
•
•
•
•
•
•
•
Change engine oil and oil filter, clean oil screens.
Check and adjust valve clearance.
x
•
x
Check engine mounting screws for tightness.
Replace spark plug.
•
•
•
•
•
•
Check engine bolts accessible from outside for tightness.
Check connection boots for cracks and leakage.
Read out the error memory with a KTM diagnostic tool.
Check fuel hoses, SLS hoses and vent hoses for damage, correct fit-
ting and leaks.
Clean, check and grease the O-ring of the fuel hose connection.
Check the cable harness of the throttle valve body for damage and cor-
rect positioning.
•
•
•
•
•
•
Fuel injection
x
•
•
•
•
•
•
x
•
•
•
•
•
•
•
x
x
•
x
Attachments
Check the cooling system for leakage.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the functioning of the radiator fan.
x
the exhaust holders are tight.
Check the exhaust system for xleaks and correct fitting and check that
•
•
•
•
•
•
•
•
•
•
Check Bowden cables for damage, smooth operation, routing without
sharp bends and setting.
Check/correct the fluid level of the hydraulic clutch. (
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check air filter and change if necessary. Clean the air filter xbox.
•
•
Check cables for damage and routing without sharp bends.
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GREASING AND SERVICE TABLE
54
K10N
K50A
K100A
J1A
•
J2A
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Attachments
Brakes
Check the functioning of the electrical equipment.
Check screws and nuts for tightness.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Change brake fluid.
x
Check brake lines for damage and leakage.
Check braking.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
x
Chassis
Check shock absorber and fork for leakage and functioning.
Clean dust boots of fork legs.
Bleed fork legs. (
Check screws and guide bolts of brake system for tightness. x
x
•
•
•
•
Check swingarm bearing.
Check play of steering head bearing.
x
Check all screws to see if they are tight.
Grease Pro‑Lever deflector.
Check rim run-out.
x
Wheels
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
x
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GREASING AND SERVICE TABLE
55
K10N
K50A
K100A
J1A
•
J2A
•
Wheels
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check rear sprocket / engine sprocket for tightness.
•
•
•
•
•
•
•
•
•
•
Check wheel bearing for play.
x
•
•
Checking the rear hub rubber dampers.
x
K10N: after 1,000 km (621.4 mi)
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
8
.2
K100A
J1A
J2A
•
•
•
Carry out a complete fork service.
x
•
Carry out a complete shock absorber service.
x
•
Clean and grease steering head bearing and sealing elements.
Treat electric contacts with contact spray.
x
•
•
•
Clean the battery terminals and treat them with contact grease.
Change coolant.
•
•
x
K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years
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MAINTENANCE WORK ON CHASSIS AND ENGINE
56
9MAINTENANCE WORK ON CHASSIS AND ENGINE
9
Jacking up the motorcycle
.1
Note
Danger of damageꢀDanger of damage by the vehicle running away or falling over.
–
Always place the vehicle on a firm and even surface.
–
–
Jack up the motorcycle on the underride guard underneath the engine. The wheels must
no longer touch the ground.
Secure the motorcycle against falling over.
100241-01
9
.2
Note
Danger of damageꢀDanger of damage by the vehicle running away or falling over.
–
Always place the vehicle on a firm and even surface.
–
–
Remove the motorcycle from the work stand and rest it on its side stand.
Remove the work stand.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
57
9
.3
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 understood as a guideline and should always be the basis
of your own personal chassis adaptation. Do not change the adjustments at random or by
more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly
at high speeds.
100242-01
9
.4
djusting compression damping of fork
Info
The hydraulic compression damping determines the fork suspension behavior.
–
–
Remove protection covers .
Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
100243-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
58
–
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Compression damping
Comfort
20 clicks
15 clicks
10 clicks
10 clicks
Standard
Sport
full payload
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
–
Mount protection covers .
9
.5
djusting rebound damping of fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
Turn adjusting screws clockwise until they stop.
–
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
100244-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
59
–
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Rebound damping
Comfort
20 clicks
15 clicks
10 clicks
10 clicks
Standard
Sport
full payload
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
9
.6
The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle.
The low- and high-speed technology works non-specifically.
9
.7
djusting the low-speed compression damping of the shock absorber
Danger
Danger of accidentsꢀThe 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.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
60
–
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.
Specification
Compression damping, low-speed
Comfort
Standard
Sport
20 clicks
15 clicks
10 clicks
10 clicks
full payload
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
100245-10
9
.8
djusting high-speed compression damping of the shock absorber
Danger
Danger of accidentsꢀThe 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.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
61
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 !
Turn back counterclockwise the number of turns corresponding to the shock absorber
type.
Specification
Compression damping, high-speed
Comfort
Standard
Sport
2 turns
1.5 turns
1 turn
full payload
1 turn
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
100246-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
62
9
.9
djusting rebound damping of the shock absorber
Danger
Danger of accidentsꢀThe 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.
–
–
Turn the adjusting screw clockwise until it stops.
Turn back counterclockwise the number of clicks corresponding to the shock absorber
type.
Specification
Rebound damping
Comfort
Standard
Sport
20 clicks
15 clicks
10 clicks
10 clicks
100247-10
full payload
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
9
.10
leeding fork legs
–
Lean the motorcycle on the side stand.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
63
–
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
9
.11
–
–
–
Push dust boots of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork tubes.
Over time, dirt can penetrate behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
Warning
Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.
100293-10
–
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.
Press the dust boots back into their normal position.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
64
–
–
–
Remove excess oil.
9
.12
–
–
–
Remove screws and take off clamp.
Remove screws on left fork leg. Push the fork protection downwards.
Remove the screws on the right fork leg. Push the fork protection downwards.
100292-10
9
.13
–
Position the fork protection on the left fork leg. Mount and tighten screws .
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
–
Position the brake line and cable harness. Put the clamp on, mount and tighten
screws .
Position the fork protection on the right fork leg. Mount and tighten screws.
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
100292-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
65
9
.14
hecking play of steering head bearing
x
Warning
Danger of accidentsꢀUnsafe 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.
–
–
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:
–
Adjust play of the steering head bearing.
x
–
Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No resting
locations should be noticeable.
100298-10
»
If click positions are noticeable:
–
Adjust play of the steering head bearing.
x
–
Check the steering head bearing and change if necessary.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
66
9
.15
djusting play of steering head bearing
x
–
–
–
Loosen screw . Remove screw .
Loosen and retighten screw .
Specification
Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Fully tighten screw .
Specification
Screw, top triple clamp
M8
17 Nm (12.5 lbf ft)
100297-10
–
Mount and tighten screw .
Specification
Screw, steering stem
M8
20 Nm
Loctite® 243™
(14.8 lbf ft)
–
–
Check play of steering head bearing.
x
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0A
MAINTENANCE WORK ON CHASSIS AND ENGINE
67
9
.16
djusting the handlebar angle
x
–
–
–
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.
»
If the handlebar instruments touch the fuel tank:
–
Correct the handlebar angle.
Info
The distance between the handlebar support and the handlebar clamp
must be the same at the front and rear.
100279-10
–
Fully tighten screw .
Specification
Screw, handlebar clamp
M8
20 Nm
Loctite® 243™
(14.8 lbf ft)
9
.17
On the upper triple clamp, there are 2 holes at a distance to each other.
Distance between holes 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance from the center.
Distance between holes 3.5 mm (0.138 in)
0B
The handlebar can be mounted in 4 different positions. In this way, the handlebar can be
installed in the position most comfortable for the rider.
400271-11
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01
MAINTENANCE WORK ON CHASSIS AND ENGINE
68
9
.18
djusting handlebar position
x
–
Remove the four screws . Remove the handlebar clamp. Remove the handlebar and
lay it to one side.
Info
02
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
–
–
Remove the two screws . Remove the handlebar support.
Place the handlebar support in the required position. Fit and tighten the two screws .
Specification
400271-10
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
–
–
Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
Position the handlebar clamp. Fit and evenly tighten the four screws .
Specification
Screw, handlebar clamp
M8
20 Nm
Loctite® 243™
(14.8 lbf ft)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
69
9
.19
hecking chain dirt
–
Check the chain for coarse dirt accumulation.
»
If the chain is very dirty:
–
9
.20
leaning the chain
Warning
Danger of accidentsꢀOil or grease on the tires reduces their grip.
–
Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidentsꢀReduced 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
The service life of the chain depends largely on its maintenance.
–
–
–
Clean the chain regularly.
Rinse off loose dirt with a soft jet of water.
Remove old grease remains with chain cleaner.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
70
–
After drying, apply chain spray.
9
.21
hecking the chain tension
Warning
Danger of accidentsꢀDanger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
71
–
–
–
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, so you should repeat this measurement at differ-
ent chain positions.
Chain tension
5 mm (0.2 in)
Distance to chain sliding guard
30 mm (1.18 in)
»
If the chain tension does not meet specifications:
–
100249-10
9
.22
djusting chain tension
Warning
Danger of accidentsꢀDanger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
72
–
–
–
–
–
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.
Specification
Chain tension
5 mm (0.2 in)
Turn the adjusting screws left and right so that the markings on the left and right
chain adjusters are in the same position relative to the reference marks . The
rear wheel is then correctly aligned.
Info
The upper chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.
–
–
–
Tighten nuts .
Make sure that the chain adjusters are fitted correctly on the adjusting screws .
Tighten nut .
100250-10
Specification
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters can be turned by 180°.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
73
9
.23
–
Check rear sprocket / engine sprocket for wear.
If the rear sprocket / engine sprocket are worn:
»
–
Replace rear sprocket / engine sprocket.
Info
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
–
Check chain guides for tightness and wear.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
74
9
.24
hecking chain wear
–
Shift into neutral, pull the lower chain section with the specified weight .
Specification
Weight of chain wear measurement
15 kg (33 lb.)
–
Measure the distance of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.
A
Maximum distance at the longest
272 mm (10.71 in)
chain section
»
If the distance is greater than the specified measurement:
–
Have the chain changed.
Info
B
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
For safety reasons, the chain has no chain joint. Always have the chain
changed in an authorized KTM workshop, where the necessary tool is
available.
1 2 3
16 17 18
400409-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
75
9
.25
djusting chain guide
x
–
Remove screws and . Take off the chain guide.
Conditions
Number of teeth: ≤ 44 teeth
–
–
Insert nut in hole . Position the chain guide.
Mount and tighten screws and .
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Conditions
Number of teeth: ≥ 45 teeth
–
–
Insert nut in hole . Position the chain guide.
Mount and tighten screws and .
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
100299-10
9
.26
hecking brake discs
Warning
Danger of accidentsꢀReduced braking due to worn brake discs.
Worn brake discs should be replaced immediately in an authorized KTM workshop.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
76
–
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..
Wear limit of brake discs
front
Rear
4.5 mm (0.177 in)
3.5 mm (0.138 in)
400406-10
»
If the brake disc thickness is less than the specified value:
Change the brake disc.
–
9
.27
hecking free play of hand brake lever
Warning
Danger of accidentsꢀBrake system failure.
–
If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can
fail due to overheating. Adjust free travel on hand brake lever according to specifications.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
77
–
Push the hand brake to the handlebar and check free play .
Free play of hand brake lever ≥ 3 mm (≥ 0.12 in)
If the free travel does not meet specifications:
»
–
100251-10
9
.28
djusting free travel of handbrake lever
–
Adjust the free travel of the handbrake lever with the adjustment screw .
Info
Turn the adjustment screw clockwise to reduce free travel. The pressure point
moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The pressure
point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
100252-10
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
78
9
.29
hecking front brake fluid level
Warning
Danger of accidentsꢀBrake 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.
Warning
Danger of accidentsꢀReduced 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 when the
brake fluid reservoir is vertical.
»
If the brake fluid level is lower than thexcenter of the level viewer:
–
Add brake fluid for the front brake.
100253-10
9
.30
dding brake fluid for front brake
x
Warning
Danger of accidentsꢀBrake 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.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
79
Warning
Skin irritationsꢀBrake fluid can cause skin irritation on contact.
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsꢀReduced 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT 5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
80
–
–
–
Remove screws .
Remove cover with membrane .
Add brake fluid to level .
Specification
Measurement of
5 mm (0.2 in)
–
–
Check parts for damage and wear. Replace damaged or worn parts.
Position the cover with the membrane. Mount and tighten screws.
100254-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
9
.31
The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties. The type names of brake pads are
entered in the homologation documents.
Info
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and
friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If
brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle
no longer corresponds to the condition at delivery, and the warranty is no longer valid.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
81
9
.32
hecking the front brake linings
Warning
Danger of accidentsꢀReduced braking due to worn brake linings.
–
Worn brake linings should be replaced immediately in an authorized KTM workshop.
Note
Danger of accidentsꢀReduced braking due to damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.
–
Check the brake linings for minimum thickness .
Minimum thickness
≥ 1 mm (≥ 0.04 in)
»
If the minimum thickness is less thxan specified:
–
Change the front brake linings.
100255-10
9
.33
hanging the front brake linings
x
Warning
Danger of accidentsꢀImproper brake maintenance and repair.
–
Always have your brake system maintained and repaired in an authorized KTM workshop.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
82
Warning
Skin irritationsꢀBrake fluid can cause skin irritation on contact.
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsꢀReduced 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
Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsꢀReduced braking due to use of non-approved brake linings.
–
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. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license.
The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
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MAINTENANCE WORK ON CHASSIS AND ENGINE
83
–
–
–
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws .
Remove the cover with membrane .
Press the brake caliper by hand on to the brake disc in order to press back the brake
pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir and
suction it off if necessary.
Info
Make sure when pushing back the brake pistons that you do not press the brake
caliper against the spokes.
100254-11
–
Remove split pin , remove bolt toward the right by striking it and remove the brake
linings.
–
–
Clean brake caliper and brake caliper support.
Check parts for damage and wear. Replace damaged or worn parts.
100290-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
84
–
Check that leaf spring in the brake caliper and sliding plate in the brake caliper
support are seated correctly.
400418-10
100291-01
100254-12
–
–
Insert the brake pads, insert the bolt and mount the split pin.
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and
there is a tight spot.
–
–
Adjust the brake fluid level to level .
Specification
Measurement of
5 mm (0.2 in)
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
85
9
.34
hecking free play of foot brake lever
Warning
Danger of accidentsꢀBrake 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. Adjust free travel on foot brake pedal according to specifications.
–
Move the foot brake lever back and forth between the end stop and the contact to the
foot brake cylinder piston and check free travel .
Specification
Free play at foot brake lever
3… 5 mm (0.12… 0.2 in)
Info
You will know that contact has been made with the foot brake cylinder piston
when there is increased resistance when you activate the foot brake pedal.
100256-10
»
If the free travel does not meet specifications:
–
Adjust the basic position of the foot brake pedal.
x
9
.35
djusting basic position of foot brake pedal
x
Warning
Danger of accidentsꢀBrake 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. Adjust free travel on foot brake pedal according to specifications.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
86
–
Remove screw connection on foot brake cylinder .
–
To adjust the basic position of the foot brake pedal as needed, loosen nut and turn
screw accordingly.
Info
The range of adjustment is limited. The screw must be screwed into the footrest
bracket by at least four turns.
–
Position foot brake cylinder so that the foot brake pedal has the necessary free travel.
Hold screws in place and tighten the nuts.
Specification
Nut, foot brake cylinder screw
M6
10 Nm (7.4 lbf ft)
–
–
Tighten nut .
100257-10
9
.36
Warning
Danger of accidentsꢀBrake 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.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
87
Warning
Danger of accidentsꢀReduced 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.
Check the brake fluid level in the brake fluid reservoir.
»
If the fluid level reaches the MIN marking :
–
Top up the brake fluid of the rear brake.
x
100258-10
9
.37
opping up brake fluid of rear brake
x
Warning
Danger of accidentsꢀBrake 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.
Warning
Skin irritationsꢀBrake fluid can cause skin irritation on contact.
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
88
Warning
Danger of accidentsꢀReduced 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
–
–
–
Stand the vehicle upright.
Remove screw cover with membrane .
Top up the brake fluid to MAX level.
–
–
Check parts for damage and wear. Replace damaged or worn parts.
Refit screw with membrane.
Info
100259-10
Clean up overflowed or spilt brake fluid immediately with water.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
89
9
.38
hecking the rear brake linings
Warning
Danger of accidentsꢀReduced braking due to worn brake linings.
–
Worn brake linings should be replaced immediately in an authorized KTM workshop.
Note
Danger of accidentsꢀReduced braking due to damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.
–
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
100260-10
9
.39
hanging rear brake linings
x
Warning
Danger of accidentsꢀImproper brake maintenance and repair.
–
Always have your brake system maintained and repaired in an authorized KTM workshop.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
90
Warning
Skin irritationsꢀBrake fluid can cause skin irritation on contact.
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsꢀReduced 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
Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsꢀReduced braking due to use of non-approved brake linings.
–
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. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license.
The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
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MAINTENANCE WORK ON CHASSIS AND ENGINE
91
–
–
–
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.
Info
Make sure when pushing back the brake piston that you do not press the brake
caliper against the spokes.
100259-10
100288-10
400419-10
–
Remove split pin , remove bolt toward the left by striking it and remove the brake
linings.
–
–
Clean brake caliper and brake caliper support.
Check parts for damage and wear. Replace damaged or worn parts.
–
Check that leaf spring in the brake caliper and sliding plate in the brake caliper
support are seated correctly.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
92
–
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.
–
–
Adjust the brake fluid level to the MAX mark.
Refit screw with membrane.
Info
100289-01
Clean up overflowed or spilt brake fluid immediately with water.
9
.40
emoving front wheel
x
–
–
Press the brake caliper by hand on to the brake disc in order to press back the brake
pistons.
100261-01
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MAINTENANCE WORK ON CHASSIS AND ENGINE
93
–
Remove screw .
–
Loosen screw .
100262-10
100263-10
100264-10
–
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the
fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not damaged.
–
Remove the spacing sleeves .
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MAINTENANCE WORK ON CHASSIS AND ENGINE
94
9
.41
itting front wheel
x
Warning
Danger of accidentsꢀReduced 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.
–
–
–
Check parts for damage and wear. Replace damaged or worn parts.
Clean and grease shaft seal rings and bearing surface of the spacing sleeves.
Fit the spacing sleeves.
–
100265-10
–
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
Mount and tighten screw .
Specification
Screw, front wheel spindle
M24x1.5
40 Nm (29.5 lbf ft)
–
Operate the hand brake lever several times until the brake pads are lying correctly on
the brake disc.
–
–
Pull the front wheel brake and push down hard on the fork several times to align the
fork legs.
100266-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
95
–
Fully tighten screw .
Specification
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
9
.42
emoving rear wheel
x
–
–
Press the brake caliper by hand on to the brake disc in order to press back the brake
piston.
–
–
Remove nut . Remove chain adjuster .
Holding the rear wheel, withdraw the wheel spindle .
100267-10
–
–
Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.
Warning
Danger of accidentsꢀReduced braking due to damaged brake discs.
–
Always lay the wheel down in such a way that the brake disc is not damaged.
Take the rear wheel out of the swing arm.
Info
Do not operate the foot brake when the rear wheel is removed.
100268-01
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MAINTENANCE WORK ON CHASSIS AND ENGINE
96
9
.43
itting rear wheel
x
Warning
Danger of accidentsꢀReduced braking due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
–
Warning
Danger of accidentsꢀNo braking effect when operating the rear brake.
–
After installing the rear wheel, always operate the footbrake until the pressure point is reached.
–
Checking the rear hub rubber dampers.
x
–
–
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 .
–
Clean and grease the thread of the wheel spindle and nut .
–
–
Mount the rubber damper and rear sprocket carrier in the rear wheel.
100269-10
Place the rear wheel in the swingarm and bring the brake disc on the brake caliper into
contact.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
97
–
Push the rear wheel forward as far as possible and place the chain on the rear sprocket.
Mount the wheel spindle, chain adjuster and nut.
Specification
–
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 reference marks .
Info
Fit the chain left and right adjusters in similar positions.
100270-10
–
Tighten nut .
Specification
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
–
–
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and
there is a tight spot.
9
.44
hecking the rear hub rubber dampers
x
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.
–
Remove the rear wheel.
x
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MAINTENANCE WORK ON CHASSIS AND ENGINE
98
–
Check rubber dampers of the rear hub for damage and wear.
If the rubber dampers of the rear hub are damaged or worn:
Change all rubber dampers in the rear hub.
»
–
100271-10
–
–
Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the
wheel spindle in the hub.
To check the play , hold the rear wheel tight and try to rotate the rear sprocket.
Info
Measure the play on the outside of the rear sprocket.
Play in rubber dampers, rear wheel
If the play is more than the specified value:
Change all rubber dampers in the rear hub.
≤ 5 mm (≤ 0.2 in)
»
100272-10
–
–
x
9
.45
ire condition checking
Warning
Danger of accidentsꢀUncontrollable handling behavior caused by a flat tire.
For your own safety, have damaged tires changed immediately.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
99
Warning
Danger of crashingꢀImpairment of riding behavior due to different tire tread patterns on front and rear wheels.
–
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidentsꢀUncontrollable handling behavior caused by non-approved tires/wheels.
–
Use only tires/wheels approved by KTM with the corresponding speed index.
Warning
Danger of accidentsꢀReduced road grip with new tires.
–
New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in
the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle
has been run in.
Info
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
–
Check the front and rear tire for cuts, penetrations and other damage.
If the tires exhibits cuts, penetrations or other damage:
Change the tires.
»
–
100273-01
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MAINTENANCE WORK ON CHASSIS AND ENGINE
100
–
Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth
If the minimum tread depth is insufficient:
Change the tires.
≥ 2 mm (≥ 0.08 in)
»
–
9
.46
hecking tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
–
Remove dust cap.
100274-01
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MAINTENANCE WORK ON CHASSIS AND ENGINE
101
–
Check tire air pressure when tires are cold.
Tire air pressure, offroad, single rider
front
1.5 bar (22 psi)
1.5 bar (22 psi)
Rear
Tire air pressure, road, solo
front
Rear
1.8 bar (26 psi)
1.8 bar (26 psi)
Tire air pressure with passenger / fully loaded
front
Rear
2.0 bar (29 psi)
2.2 bar (32 psi)
»
If the tire pressure does not meet specifications:
Correct tire pressure.
Mount dust cap.
–
–
9
.47
hecking spoke tension
Warning
Danger of accidentsꢀUnstable 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.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
102
–
To check spoke tension, tap each spoke with a screwdriver.
Specification
You should hear a high note.
Spoke nipple, front wheel
Spoke nipple, rear wheel
M5
M5
4 Nm (3 lbf ft)
4 Nm (3 lbf ft)
Info
If you hear different tone frequencies from different spokes, this is an indication
of different spoke tensions.
100275-01
9
.48
–
–
Pull on strap and raise the rear of the seat at the same time.
Pull back the seat and lift it off.
100230-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
103
9
.49
ounting the seat
–
–
–
Hook slot of the seat onto screw , press the rear downward and at the same time
push it forward.
Push locking pin into lock housing and push the back of the seat down until the
locking pin locks in place with an audible click.
Finally, check that the seat is correctly mounted.
100276-10
9
.50
emoving the battery
x
Warning
Risk of injuryꢀBattery 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.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a doctor.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
104
–
–
–
–
–
–
–
Disconnect the negative (minus) cable of the battery.
Pull off connector in an upward direction.
Remove screws .
Pull retaining bracket of the battery forward and remove it.
Take off the positive terminal cover .
Disconnect the positive (plus) cable of the battery.
Press the wiring harness to one side and pull the battery out of the battery rack.
100277-10
Info
Never operate the motorcycle with a discharged battery or without a battery. In
both cases, electrical components can safety equipment can be damaged. The
vehicle is then no longer safe to ride.
9
.51
nstalling the battery
x
–
Slide the battery into the battery rack.
Info
The battery terminals must be at the rear.
–
–
–
Attach the positive cable and mount positive terminal cover .
Position retaining bracket .
Mount and tighten screws .
Specification
100277-11
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
–
–
Plug in connector .
Attach the minus cable .
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MAINTENANCE WORK ON CHASSIS AND ENGINE
105
–
9
.52
echarging the battery
x
Warning
Risk of injuryꢀBattery 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.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a doctor.
Warning
Environmental hazardꢀComponents 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
106
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The
battery capacity is then reduced.
If the battery becomes discharged from starting, it must be recharged immediately.
If the battery rests for an extended time in a discharged state, it becomes over-discharged and sulfated, which will result in its
destruction.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–
–
Switch off all power-consuming components and switch off the engine.
x
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MAINTENANCE WORK ON CHASSIS AND ENGINE
107
–
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 .
Charge the battery according to the instructions on the battery casing.
–
–
After charging, switch off and disconnect the battery charger.
Specification
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use.
3 months
Install the battery.
x
100151-10
9
.53
hanging the main fuse
Warning
Fire hazardꢀThe electrical system can be overloaded by the use of incorrect fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
108
Info
The main fuse protects all power-consuming components of the vehicle. It is located in the housing of the electric starter relay next
to the battery.
–
–
–
Switch off all power-consuming components and switch off the engine.
Remove protection covers .
600604-10
–
–
Remove a defective main fuse with a needle nose plier.
Check parts for damage and wear. Replace damaged or worn parts.
Info
A reserve fuse is located in the starter relay.
–
Fit a new main fuse.
600605-10
Info
If the new fuse burns out, contact an authorized KTM workshop.
–
Check the functioning of the electrical equipment.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
109
–
–
–
Attach the protection covers.
9
.54
hanging fuses of individual power consumers
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
–
–
–
Switch off all power-consuming components and switch off the engine.
Open the fuse box cover .
600604-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
110
–
Remove defective fuse.
Specification
Fuse 1 - 10A - ignition, combination instrument, alarm system (optional)
Fuse 2 - 10A - clock, ignition (EFI control unit)
Fuse 3 - 10A - throttle valve control unit
Fuse 4 - 10A - fuel pump
Fuse 5 - 10A - radiator fan
Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional)
Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 8 - 10A - for supplementary equipment (accessories connected with ignition
switch)
Fuse 9 - 10A - for supplementary equipment (standard accessories)
Fuse 10 - not used
Fuse SPARE - 10A/15A - spare fuses
–
Check parts for damage and wear. Replace damaged or worn parts.
Info
600606-10
A defective fuse is shown by a burned-out fuse wire .
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MAINTENANCE WORK ON CHASSIS AND ENGINE
111
Warning
Fire hazardꢀThe electrical system can be overloaded by the use of incorrect
fuses.
–
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
–
Use spare fuses with the correct rating only.
Info
If the new fuse burns out, contact an authorized KTM workshop.
Tip
Replace the spare fuse in the fuse box so that it will be available if needed.
–
–
–
Check the functioning of the power consumer.
Close the fuse box cover.
9
.55
–
–
Switch off the ignition by turning the ignition key in the position
.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
112
–
Pull the Map‑Select switch and holder upward off of the retaining bracket.
–
Pull the Map‑Select switch out of the holder.
100237-10
–
Turn the adjusting wheel until the desired digit is next to marking .
Set the Map‑Select switch to Soft.
–
Set the adjusting wheel to position 1.
Soft – reduced homologated peak performance for better driveability.
Set the Map‑Select switch to Advanced.
–
Set the adjusting wheel to position 2.
Advanced – homologated performance with extremely direct responsiveness.
Set the Map‑Select switch to Standard.
100238-10
–
Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.
Standard – homologated performance with balanced responsiveness.
Set the Map‑Select switch to poor fuel quality.
Set the adjusting wheel to position 0.
–
Poor fuel quality – homologated performance is reduced in accordance with the
fuel quality, use for no more than 1 tank of fuel
–
–
–
Position the Map‑Select switch in the holder.
Slide the Map‑Select switch with the holder downward onto the retaining bracket.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
113
9
.56
–
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.
–
–
–
Tilt the headlight mask forward and lift it off.
600607-10
–
–
Disconnect the connectors of flasher lights and headlight .
Place the headlight mask to one side.
100294-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
114
9
.57
–
–
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
and swing it up to the steering head.
100295-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
115
–
Position brake-hose guide . Mount and tighten screws .
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
100296-10
9
.58
Note
Damage to reflectorꢀKeep the glass of the bulb free of grease.
–
Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the
reflector.
–
–
–
Pull off connector .
Take off rubber cap of the headlight bulb.
600610-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
116
–
–
–
Detach spring bar .
Remove headlight bulb .
Insert a new headlight bulb into the headlight housing.
–
–
–
Fit the headlight bulb in the headlight using the spring bar.
Replace the rubber cap. Attach the connector.
600611-10
9
.59
Note
Damage to reflectorꢀKeep the glass of the bulb free of grease.
–
Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the
reflector.
–
–
Remove rubber cap .
600610-12
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MAINTENANCE WORK ON CHASSIS AND ENGINE
117
–
–
–
–
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.
–
–
–
Insert the bulb socket into the reflector.
Insert the rubber cap.
600612-10
9
.60
Note
Damage to reflectorꢀKeep the glass of the bulb free of grease.
–
Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the
reflector.
–
–
–
–
Remove the screw on the rear of the flasher housing.
Carefully swing the diffuser forwards and remove it.
Lightly pinch the orange cap at the holding points and remove it.
Press the flasher bulb carefully into the holder, turn it about 30° counterclockwise and
remove it from the holder.
Info
Do not touch the reflector with your fingers and try to avoid contact with oil or
grease.
100301-10
–
Check parts for damage and wear. Replace damaged or worn parts.
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0A
MAINTENANCE WORK ON CHASSIS AND ENGINE
118
–
Press the new flasher bulb carefully into the holder and turn it clockwise as far as it will
go.
–
–
–
Mount the orange cap.
Position the diffuser.
Insert the screw and turn it first counterclockwise until you feel it click into the thread.
Tighten the screw.
–
Check the flasher function.
9
.61
–
–
On a light-colored wall with a horizontal area in front of it, make a mark as high as the
center of the low beam headlight.
Make another mark at a distance of under the first mark.
Specification
Distance
5 cm (2 in)
0B
–
–
Stand the motorcycle at a distance of in front of the wall and switch on the low
beam.
Specification
400408-10
Distance
5 m (16 ft)
Check the headlamp setting.
The boundary between light and dark must be exactly on the lower mark for a motor-
cycle with driver.
»
If the boundary between light and dark does not meet specifications:
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
119
9
.62
–
–
Use a screwdriver (see illustration) to adjust the headlight range.
Specification
The boundary between light and dark must be exactly on the lower mark for a motor-
cycle with a rider (mark is applied under: Checking headlight adjustment).
Info
Turn clockwise to increase the light range, turn counterclockwise to reduce the
light range.
If you have a payload, you may have to correct the headlight range.
600613-01
9
.63
emoving the air filter
x
–
–
Remove screws . Remove filter box top .
100285-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
120
Note
Engine failureꢀUnfiltered 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.
–
–
Remove air filter .
100286-10
9
.64
nstalling the air filter
x
Check parts for damage and wear. Change damaged or worn parts. Change the air filter
if it is dirty or wet.
–
–
Clean the air filter box.
Mount air filter .
Info
The air filter must be in contact with the air filter box along the entire sealing
surface .
–
Attach filter box top at the front of the air filter box and swing it down.
100287-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
121
–
Mount and tighten screws .
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
100285-11
9
.65
The water pump in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve in
the radiator cap . Heat expansion causes excess coolant to flow into the compensating
tank . If the temperature falls, the excess coolant is sucked back into the cooling system.
The specified coolant temperature is therefore permissible without danger of function prob-
lems.
125 °C (257 °F)
600614-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
122
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.
400407-10
9
.66
hecking the antifreeze and coolant level
Warning
Danger of scaldingꢀThe coolant gets very hot when the motorcycle is driven and is under high pressure.
–
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool-
ing system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningꢀCoolants 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. Keep coolants out of the reach of children.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
123
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)
»
If the antifreeze of the cooling liquid does not meet specifications:
Correct antifreeze of coolant.
–
100283-10
–
Check the coolant level in the compensating tank.
The coolant level must be within the range shown in the figure.
»
If the level of the cooling liquid does not meet specifications:
–
Correct the coolant level.
Alternative 1
Alternative 2
–
Mount the cap of the compensating tank.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
124
–
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.
The radiator must be completely full.
100284-10
»
If the level of the cooling liquid does not meet specifications:
–
Correct the coolant level and find out the cause of the loss.
Alternative 1
Alternative 2
–
Refit the radiator cap.
9
.67
hecking the coolant level
Warning
Danger of scaldingꢀThe coolant gets very hot when the motorcycle is driven and is under high pressure.
–
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool-
ing system to cool down. If you scald yourself, hold the affected area under cold water immediately.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
125
Warning
Danger of poisoningꢀCoolants 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. Keep coolants out of the reach of children.
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.
»
If the level of the cooling liquid does not meet specifications:
–
Correct the coolant level.
Alternative 1
100283-10
Alternative 2
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MAINTENANCE WORK ON CHASSIS AND ENGINE
126
–
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.
Alternative 1
Alternative 2
100284-10
–
Refit the radiator cap.
9
.68
raining coolant
x
Warning
Danger of scaldingꢀThe coolant gets very hot when the motorcycle is driven and is under high pressure.
–
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool-
ing system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningꢀCoolants 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. Keep coolants out of the reach of children.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
127
–
–
–
–
–
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.
Specification
Plug, drain hole of water pump
M10x1
15 Nm (11.1 lbf ft)
–
600616-10
9
.69
illing the cooling system
x
Warning
Danger of poisoningꢀCoolants 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. Keep coolants out of the reach of children.
–
–
Stand the motorcycle on its side stand on a horizontal surface.
Remove radiator cap .
600618-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
128
–
Refill the coolant.
Alternative 1
Alternative 2
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
figure.
Mount the cap of the compensating tank.
Danger
Danger of poisoningꢀExhaust 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.
100283-11
–
–
–
Start the engine and run it until the 5th bar of the temperature indicator lights up.
Switch off the engine and allow it to cool down.
After the engine has cooled down, check the coolant level in the radiator and in the
compensating tank again and add more coolant if necessary.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
129
9
.70
djusting basic position of clutch lever
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.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
100282-10
9
.71
hecking/correcting fluid level of hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
–
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
130
–
–
–
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:
Correct the fluid level of the hydraulic clutch.
–
100281-10
–
–
Check parts for damage and wear. Replace damaged or worn parts.
Position the cover with the membrane. Mount and tighten screws.
9
.72
hecking play in gas Bowden cable
–
Move the handlebar to the straight-ahead position. Move the throttle grip backwards
and forwards to ascertain the play in the gas Bowden cable.
Play in gas Bowden cable
3… 5 mm (0.12… 0.2 in)
»
If the gas Bowden cable play does not meet sxpecifications:
–
Adjust the play in the gas Bowden cable.
400192-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
131
Danger
Danger of poisoningꢀExhaust 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.
–
Start the engine and let it run idle. Move the handlebar to and fro over the entire steer-
ing range.
The idle speed must not change.
»
If the idle speed changes:
–
Adjust the play in the gas Bowden cable.
x
9
.73
djusting play in gas Bowden cable
x
–
–
–
Move the handlebar to the straight-ahead position.
Loosen the lock nut .
Adjust the play in the gas Bowden cable by turning the adjusting screw .
Specification
Play in gas Bowden cable
3… 5 mm (0.12… 0.2 in)
–
Tighten the lock nut .
100280-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
132
9
.74
–
–
–
Stand the motorcycle on its side stand on a horizontal surface.
Remove screws on the left and right.
Pull the engine guard forward out of the holders and set it down.
100198-10
9
.75
–
–
Slide the engine guard into holders at the rear.
Position the engine guard. Mount and tighten screws.
Specification
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
100199-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
133
9
.76
hecking engine oil level
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.
–
Check the engine oil level.
Info
After switching off the engine, wait for one minute and then check.
The engine oil must be between the lower and upper edge of the oil level viewer.
If the engine oil level is not at the specified level:
»
100210-10
–
9
.77
hanging engine oil and oil filter, cleaning oil screens
x
–
–
–
–
–
x
Clean oil screens.
Mount the oil filter.
Remove the oil filtxer.
x
Fill up with engine oil.
x P. 137)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
134
9
.78
raining engine oil
x
Warning
Danger of scaldingꢀEngine 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the engine oil only when the engine is warm.
–
–
–
–
Place a suitable container under the engine.
Remove the oil drain plug with the magnet and seal ring.
Completely drain the engine oil.
100200-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
135
–
–
–
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.
Specification
Oil drain plug with magnet
M12x1,5
20 Nm (14.8 lbf ft)
100201-01
9
.79
emoving the oil filter
x
Warning
Danger of scaldingꢀEngine 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
–
Place a suitable container under the engine.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
136
–
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.
Pull the oil filter insert out of the oil filter casing.
Circlip pliers reverse (51012011000)
–
–
Completely drain the engine oil.
Thoroughly clean parts and sealing area.
100203-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
137
9
.80
ounting oil filter
x
–
–
–
–
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 .
Mount and tighten screws.
Specification
Screw, oil filter cover
M5
6 Nm (4.4 lbf ft)
100204-10
9
.81
leaning oil screens
x
Warning
Danger of scaldingꢀEngine 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
–
Place a suitable container under the engine.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
138
–
Remove the plug with the oil screen and O-rings.
100205-10
100206-10
100207-10
–
–
–
–
Remove the plug with the oil screen and O-rings.
Drain the remaining engine oil.
Thoroughly clean parts and sealing area.
Check parts for damage and wear. Replace damaged or worn parts.
–
–
Position oil screen with O-rings.
Refit plug with O-ring and tighten it.
Specification
Plug, oil screen
M20x1,5
15 Nm (11.1 lbf ft)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
139
–
Position oil screen with O-rings.
Refit plug with O-ring and tighten it.
Specification
–
Plug, oil screen
M20x1,5
15 Nm (11.1 lbf ft)
100208-10
9
.82
illing up with engine oil
x
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.
Refit plug with O-ring and tighten it.
Danger
Danger of poisoningꢀExhaust 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.
100209-10
–
–
–
Start the engine and check that it is oil-tight.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
140
9
.83
opping up engine oil
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.
Refit plug with O-ring and tighten it.
Danger
Danger of poisoningꢀExhaust 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.
100209-10
–
–
Start the engine and check that it is oil-tight.
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TROUBLESHOOTING
141
1T0ROUBLESHOOTING
Faults
Possible cause
Action
Engine does not turn when the electric
starter button is pressed
Operating error
–
Carry out the instructions for starting.
Battery discharged
–
–
–
Recharge the battery.
x
Check the cause of discharging.
Fuse 1, 2, 3, or 4 blown
Change the fuses of individual power
Main fuse burned out
–
–
Ignition/steering lock or emergency OFF
switch defective
Have ignition/steering lock or emergency
OFF switch checked.
Defect in safety start system
The vehicle is in gear
–
–
–
Have the safety start system checked.
Shift gear to neutral.
Engine turns only if the clutch lever is
drawn
The vehicle is in gear and the side stand is
folded out
Shift gear to neutral.
Defect in safety start system
Defect in safety start system
Operating error
–
–
–
Have the safety start system checked.
Have the safety start system checked.
Carry out the instructions for starting.
Engine turns although a gear is engaged
Engine turns but does not start.
Fuse 4 blown
–
–
–
–
–
Change the fuses of individual power
Coupling of fuel hose connection not con-
nected
Reconnect coupling of fuel hose connec-
tion.
Socket connector of cable harness oxidized
Defect in fuel injection system
Air filter very dirty
Clean socket connector and treat it with
contact spray.
Read the error memory with the KTM
diagnostics tool and correct the fault.
Engine has too little power.
Have the air filter changed.
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TROUBLESHOOTING
142
Faults
Possible cause
Action
Engine has too little power.
Fuel filter very dirty
Defect in fuel injection system
–
–
Have the fuel filter changed.
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.
Clean radiator fins.
Radiator fins very dirty
Foam formation in cooling system
Drain the coolant.
x
Fill the cooling system.
( x
Buckled or damaged radiator hose
Thermostat defective
Fuse 5 blown
Have the radiator hose changed.
Have thermostat checked.
Change the fuses of individual power
Defect in radiator fan system
Air in cooling system
–
–
–
Have the radiator fan system checked.
Fill the cooling system.
x
FI warning lamp (MIL) lights/flashes
Defect in fuel injection system
Read the error memory with the KTM
diagnostics tool and correct the fault.
Engine dies during the journey
Lack of fuel
–
–
Fuse 1, 2 or 4 blown
Change the fuses of individual power
High oil consumption
Engine vent hose bent
–
Route the vent hose without bends or
change it if necessary.
Engine oil level too high
–
–
Engine oil too thin (low viscosity)
Change engine oil and oil filter, clean oil
screens.
x
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TROUBLESHOOTING
143
Faults
Possible cause
Action
Headlight and parking light not functioning Fuse 7 blown
–
–
–
Change the fuses of individual power
Flasher light, brake light and horn not
functioning
Fuse 6 blown
Change the fuses of individual power
Time is not (correctly) displayed
Fuse 2 blown
Change the fuses of individual power
–
–
Battery discharged
Ignition not switched off when vehicle was
parked
Recharge the battery.
x
Battery is not charged by generator
–
–
Check charging voltage.
Combination instrument shows nothing in
the display
Fuse 1 blown
Change the fuses of individual power
Speedometer in combination instrument
not functioning
Speedometer cable harness damaged or
plug oxidized
–
Have the cable harness and plug
checked.
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FLASHING CODE
144
1F1LASHING CODE
Fault
Description
Possible cause
Action
02
06
08
09
FI warning lamp (MIL) flashes
briefly 2x
Malfunction in ignition pulse
generator circuit
–
generator.
Check the throttle valve sen-
sor.
Check the throttle grip sen-
sor.
Check the xignition pulse
FI warning lamp (MIL) flashes
briefly 6x
Input signal from throttle valve
sensor too low/high
–
–
–
x
x
FI warning lamp (MIL) flashes
briefly 8x
Input signal from throttle grip
sensor too low/high
FI warning lamp (MIL) flashes
briefly 9x
Input signal from pressure sen-
sor of induction manifold too
low/high
Check the pressure sen-
sor of the induction mani-
fold.
Check the temperature sen-
sor coolant.
Check the intake air temper-
ature sensor.
Check the ambient air pres-
sure sensor.
Check the roll angle sen-
sor.
Check the lambda probe.
x
12
13
14
15
17
24
25
26
FI warning lamp (MIL) flashes 1x Input signal from coolant tem-
long, 2x short perature sensor too low/high
FI warning lamp (MIL) flashes 1x Input signal from intake air
long, 3x short temperature sensor too low/high
FI warning lamp (MIL) flashes 1x Input signal from ambient air
long, 4x short pressure sensor too low/high
FI warning lamp (MIL) flashes 1x Input signal from roll angle sen-
long, 5x short sor too low/high
FI warning lamp (MIL) flashes 1x Malfunction in lambda probe
long, 7x short circuit
FI warning lamp (MIL) flashes 2x Malfunction in voltage supply
long, 4x short circuit of EFI control unit
FI warning lamp (MIL) flashes 2x Malfunction in side stand
long, 5x short switch circuit
FI warning lamp (MIL) flashes 2x Malfunction in Hall sensor
long, 6x short throttle valve control circuit
–
–
–
–
–
–
–
–
x
x
x
x
x
Check the EFI control unit
voltage supply.
Check the side stand
switch.
Check the Hall sensor throt-
tle valve control.
x
x
x
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FLASHING CODE
145
Fault
Description
Possible cause
Action
27
FI warning lamp (MIL) flashes 2x Malfunction in voltage supply
–
long, 7x short
circuit of throttle valve control
unit
trol unit voltage supply.
Check the throttle valve xcon-
33
37
41
45
FI warning lamp (MIL) flashes 3x Malfunction in injection valve
long, 3x short circuit
FI warning lamp (MIL) flashes 3x Malfunction in ignition coil cir-
long, 7x short cuit
FI warning lamp (MIL) flashes 4x Fault/short-circuit in fuel pump
long, 1x short control circuit
FI warning lamp (MIL) flashes 4x Malfunction or short-circuit
–
–
–
–
valve.
Check the ignition coil.
Checkxthe injection
x
trol.
Checxk the fuel pump con-
Check thxe lambda probe
long, 5x short
after positive in lambda probe
heating.
heating circuit
54
55
58
FI warning lamp (MIL) flashes 5x Fault/short-circuit in secondary
long, 4x short air valve circuit
FI warning lamp (MIL) flashes 5x Malfunction in throttle valve
long, 5x short control unit circuit (internal)
FI warning lamp (MIL) flashes 5x Malfunction in release of throt-
long, 8x short tle stepper in EPT mode
–
–
–
–
–
–
valve.
Check the throttle valve con-
trol unit.
Check the throttle valve con-
trol unit.
Check the EFI control
unit.
Check the throttle stepper
motor.
Checkxthe secondary air
x
x
x
x
60
68
FI warning lamp (MIL) flashes 6x Malfunction in throttle stepper
long circuit
FI warning lamp (MIL) flashes 6x Connection of pressure sensor
long, 8x short of induction manifold leaky
Check the connection of
the pressure sensor of the
induction manifold.
Check the throttle valve
position.
x
90
FI warning lamp (MIL) flashes 9x Throttle valve position not plau-
long sible
–
x
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FLASHING CODE
146
Fault
Description
FI warning lamp (MIL) flashes 9x Malfunction in CAN bus com-
long, 1x short munication
FI warning lamp (MIL) flashes 9x Malfunction in voltage supply
Possible cause
Action
91
–
Check CAN bus communica-
tion.
Check the throttle valve con-
trol unit.
x
92
–
long, 2x short
circuit of throttle valve control
x
unit (internal)
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CLEANING
147
1C2LEANING
1
2.1
Note
Material damageꢀDamage 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 hazardꢀProblem materials cause environmental damage.
–
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
–
–
–
Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
First remove coarse dirt particles with a gentle water spray.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.
–
After rinsing the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
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CLEANING
148
Warning
Danger of accidentsꢀReduced 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.
–
–
–
–
Push back the protection covers on the handlebar instruments to allow water to evaporate.
After the motorcycle has cooled off, oil or grease all moving parts and bearings.
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
Treat all painted parts with a mild paint polish.
–
–
–
To prevent electrical problems, treat electric contacts and switches with contact spray.
Oil the ignition/steering lock.
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CONSERVATION FOR WINTER OPERATION
149
1C3ONSERVATION FOR WINTER OPERATION
1
3.1
onservation 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.
If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.
–
–
Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance.
Info
To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs.
After use on salted roads, clean the motorcycle thoroughly with cold water and dry it properly.
–
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STORAGE
150
1S4TORAGE
1
4.1
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should
do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the
new season.
–
–
–
–
–
–
–
Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.
Change engine oil and oil filter, clean oil screens.
x
Remove the battery.
Recharge the battery.
Specification
x
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.
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STORAGE
151
–
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.
1
4.2
utting into operation after storage
–
–
–
–
–
–
–
Recharge the battery.
Install the battery.
x
Make a test ride.
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TECHNICAL DATA - ENGINE
152
1T5ECHNICAL DATA - ENGINE
Design
1-cyliner 4-stroke engine, water-cooled
654 cm³ (39.91 cu in)
Displacement
Stroke
80 mm (3.15 in)
Bore
102 mm (4.02 in)
Compression ratio
Control
11,8:1
OHC, 4 valves controlled via rocker arm, chain drive
40 mm (1.57 in)
Valve diameter, intake
Valve diameter, exhaust
Valve play, cold
Crankshaft bearing
Conrod bearing
Piston pin bearing
Pistons
34 mm (1.34 in)
0.07… 0.13 mm (0.0028… 0.0051 in)
2 roller bearings
Needle bearing
Bronze bush
Forged light alloy
Piston rings
Engine lubrication
Primary transmission
Clutch
1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Pressure circulation lubrication with 2 rotor pumps
36:79
APTC antihopping clutch in oil-bath / hydraulically actuated
6-gears, claw-shifted
Gearbox
Transmission ratio
1st gear
14:35
16:28
21:28
21:23
23:22
2nd gear
3rd gear
4th gear
5th gear
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TECHNICAL DATA - ENGINE
153
6th gear
Mixture preparation
Ignition
23:20
Electronic fuel injection
Contactless controlled fully electronic ignition with digital ignition
adjustment
Generator
12 V, 224 W
Spark plug
NGK LKAR 8AI - 9
spark plug electrode gap
Cooling
0.9 mm (0.035 in)
Water cooling, permanent circulation of coolant by water pump
Electric starter, automatic decompressor
Starting aid
1
5.1
Engine oil
1.70 l (1.8 qt.)
1.20 l (1.27 qt.)
C
5.2
apacity - coolant
Coolant
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
154
1T6ECHNICAL DATA - ENGINE TIGHTENING TORQUES
Loctite® 243™
Loctite® 243™
Loctite® 243™
–
Plug, oil bore
self-tapping
M3
9 Nm (6.6 lbf ft)
2.5 Nm (1.84 lbf ft)
2 Nm (1.5 lbf ft)
1.5 Nm (1.11 lbf ft)
6 Nm (4.4 lbf ft)
3 Nm (2.2 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
4 Nm (3 lbf ft)
Screw, membrane fixation
Oil jet, conrod lubrication
Hose clamp, intake flange
Screw, cover plate for oil return line
Screw, breather cover on valve cover
Screw, gear sensor
M4
M4
M5
–
Loctite® 243™
Loctite® 243™
–
M5
M5
Screw, clutch spring
M5
Loctite® 648™
Locking screw for bearing
Screw, oil filter cover
M5
M5
–
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
–
Screw, oil pump cover
M5
Oil jet, piston cooling
M6x0.75
M6
Screw, locking lever
10 Nm (7.4 lbf ft)
3… 4 Nm (2.2… 3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
Screw, Autodecompression
Screw, axial lock of camshaft
Screw, timing chain guide rail
Screw generator cover
M6
M6
M6
M6
Loctite® 243™
Screw in generator cover (chain shaft
through-hole)
M6
Loctite® 243™
Screw, ignition pulse generator
Screw, rocker arm shaft
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
12 Nm (8.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
M6
–
M6
–
Loctite® 243™
Screw, clutch slave cylinder
Screw, clutch slave cylinder
M6x20
M6x35
–
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
155
Screw, engine housing
Screw, shift drum locating
Screw, shift lever
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M8
M8
M10x1
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
20 Nm (14.8 lbf ft)
10 Nm (7.4 lbf ft)
–
Loctite® 243™
Loctite® 222
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
–
Screw, timing chain tensioning rail
Screw, starter motor
Screw, stator bracket
Screw, thermostat housing
Screw, valve cover
Screw, water pump cover
Screw, water pump wheel
Screw, cylinder
–
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
–
Screw, cylinder head
Plug, vacuum connection
Stud, exhaust flange
Plug, crankshaft location
Screw, unlocking of timing chain ten-
sioner
–
Plug, drain hole of water pump
Plug, oil bore for oil radiator
Plug, oil bore
M10x1
M10x1
M10x1
15 Nm (11.1 lbf ft)
15 Nm (11.1 lbf ft)
15 Nm (11.1 lbf ft)
–
–
Loctite® 243™
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
156
Screw, cylinder head
M10
Tightening sequence:
Tighten diagonally, beginning
with the rear screw on the
chain shaft.
lubricated with engine oil
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)
Spark plug
M12x1,25
M12x1.5
17 Nm (12.5 lbf ft)
12 Nm (8.9 lbf ft)
–
–
Coolant temperature sensor on cylinder
head
Oil drain plug with magnet
Oil pressure regulator valve plug
Plug, oil bore
M12x1,5
M12x1.5
M14x1,5
M16x1.5
M18x1,5
M20x1,5
M20x1,5
M20LHx1,5
M20x1,5
M20x1,5
M24x1.5
M24x1,5
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
100 Nm (73.8 lbf ft)
60 Nm (44.3 lbf ft)
100 Nm (73.8 lbf ft)
100 Nm (73.8 lbf ft)
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
8 Nm (5.9 lbf ft)
–
–
Loctite® 243™
Loctite® 243™
Engine case stud
Ignition rotor nut
–
Loctite® 243™
Nut, engine sprocket
Nut, inner clutch hub
Nut, primary gear
Loctite® 243™
Loctite® 243™
Plug, oil screen
–
–
–
–
Plug, timing chain tensioner
Screw in generator cover
Plug, oil thermostat
15 Nm (11.1 lbf ft)
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TECHNICAL DATA - CHASSIS
Frame
157
Lattice frame made of chrome molybdenum steel tubing, powder-
1T7ECHNICAL DATA - CHASSIS
coated
Fork
WP 4860 MXMA
Shock absorber
WP Suspension 4618 with Pro‑Lever deflector
Suspension travel
front
250 mm (9.84 in)
250 mm (9.84 in)
Rear
Brake system
front
Disc brake with dual-piston brake caliper, floating
Disc brake with single-piston brake caliper, floating
Rear
Diameter of brake discs
front
300 mm (11.81 in)
240 mm (9.45 in)
Rear
Wear limit of brake discs
front
4.5 mm (0.177 in)
3.5 mm (0.138 in)
Rear
Tire air pressure, road, solo
front
1.8 bar (26 psi)
1.8 bar (26 psi)
Rear
Tire air pressure with passenger / fully loaded
front
2.0 bar (29 psi)
2.2 bar (32 psi)
Rear
Tire air pressure, offroad, single rider
front
Rear
1.5 bar (22 psi)
1.5 bar (22 psi)
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TECHNICAL DATA - CHASSIS
158
Rear wheel gearing
15:45
Chain
5/8 x 1/4” X‑ring
63°
Steering head angle
Wheelbase
1,498±15 mm (58.98±0.59 in)
910 mm (35.83 in)
300 mm (11.81 in)
138.5 kg (305.3 lb.)
150 kg (331 lb.)
200 kg (441 lb.)
350 kg (772 lb.)
Seat height unloaded
Ground clearance unloaded
Weight without fuel
Maximum permissible front axle load
Maximum permissible rear axle load
Maximum permissible overall weight
Battery
YTZ10S
Battery voltage: 12 V
Nominal capacity: 8.6 Ah
maintenance-free
Fuse
Fuse
Fuse
58011109130
75011088015
75011088010
30 A
15 A
10 A
1
7.1
ighting equipment
Headlight
H4/P43t
12 V
60/55 W
Parking light
W2,1x9,5d
12 V
5 W
Instrument lights and indicator lamps
Flasher light
LED
BA15s
12 V
10 W
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TECHNICAL DATA - CHASSIS
159
Brake / tail light
LED
Licence plate lamp
W2,1x9,5d
12 V
5 W
Front tire
Rear tire
90/90 - 21 54 H TL
140/80 - 18 70 H TL
Metzeler Enduro 3 Sahara
Metzeler Enduro 3 Sahara
For further information, see the Service section under:
http://www.ktm.com
1
7.2
apacity - fuel
Fuel tank content
Fuel reserve
12 l (3.2 US gal)
2.5 l (2.6 qt.)
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TECHNICAL DATA - FORK
160
1T8ECHNICAL DATA - FORK
Fork part number
14.18.7D.11
Fork
WP 4860 MXMA
Compression damping
Comfort
20 clicks
15 clicks
10 clicks
10 clicks
Standard
Sport
full payload
Rebound damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
full payload
10 clicks
Spring length with preload spacer(s)
Spring rate
472 mm (18.58 in)
Weight of rider: 75… 85 kg (165… 187 lb.)
Air chamber length
Fork length
5.4 N/mm (30.8 lb/in)
110±20 mm (4.33±0.79 in)
890 mm (35.04 in)
SAE 5
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TECHNICAL DATA - SHOCK ABSORBER
161
1T9ECHNICAL DATA - SHOCK ABSORBER
Shock absorber part number
15.18.7D.11
Shock absorber
WP Suspension 4618 with Pro‑Lever deflector
Compression damping, high-speed
Comfort
2 turns
1.5 turns
1 turn
Standard
Sport
full payload
1 turn
Compression damping, low-speed
Comfort
20 clicks
15 clicks
10 clicks
10 clicks
Standard
Sport
full payload
Rebound damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
full payload
10 clicks
Spring preload
19 mm (0.75 in)
Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.)
80 N/mm (457 lb/in)
220 mm (8.66 in)
Spring length
Gas pressure
Static sag
10 bar (145 psi)
25 mm (0.98 in)
Riding sag
80… 90 mm (3.15… 3.54 in)
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TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
163
2T0ECHNICAL DATA - CHASSIS TIGHTENING TORQUES
Remaining screws, chassis
Spoke nipple, front wheel
Spoke nipple, rear wheel
Screw, exhaust heat shield
Screw, electrical holder
Screw, footbrake pedal foothold
Screw, fuel pump
M5
M5
M5
M5
M5
M5
M5
M5
M5
M5
M5
M5
M5
M6
M6
M6
M6
4 Nm (3 lbf ft)
–
4 Nm (3 lbf ft)
–
4 Nm (3 lbf ft)
–
8 Nm (5.9 lbf ft)
3 Nm (2.2 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
3 Nm (2.2 lbf ft)
2 Nm (1.5 lbf ft)
5 Nm (3.7 lbf ft)
3 Nm (2.2 lbf ft)
3 Nm (2.2 lbf ft)
3 Nm (2.2 lbf ft)
10 Nm (7.4 lbf ft)
15 Nm (11.1 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
5 Nm (3.7 lbf ft)
14 Nm (10.3 lbf ft)
14 Nm (10.3 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
–
–
Loctite® 243™
–
Screw, fuel level indicator
Screw, side cover
–
–
Screw, headlight mask
–
Screw, side stand switch
Screw, seat lock
–
Loctite® 222
Screw, starter cable on starter
Nut, foot brake cylinder screw
Remaining nuts, chassis
Remaining screws on fuel tank
Remaining screws, chassis
–
–
–
–
–
Screw, brake fluid reservoir of rear brake M6
–
Loctite® 243™
Loctite® 243™
–
Screw, rear brake disc
M6
M6
M6
M6
Screw, front brake disc
Screw, license plate holder, bottom
Loctite® 243™
Screw, ball joint of push rod on foot-
brake cylinder
Screw, radiator bracket
M6
5 Nm (3.7 lbf ft)
–
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TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
164
Loctite® 243™
Screw, magnetic holder on side stand
Screw, voltage regulator/rectifier
Screw, SLS valve
M6
M6
M6
M6
M8
M8
M8
M8
M8
M8
M8
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
–
4 Nm (3 lbf ft)
–
Loctite® 243™
Screw, ignition lock
10 Nm (7.4 lbf ft)
35 Nm (25.8 lbf ft)
25 Nm (18.4 lbf ft)
30 Nm (22.1 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
Loctite® 243™
Nut, rear sprocket screw
Nut, manifold on cylinder head
Remaining nuts, chassis
Copper paste
–
Remaining screws, chassis
Screw, exhaust clamp on main silencer
Screw, front brake caliper
Screw, main silencer holder
–
–
Loctite® 243™
–
Loctite® 243™
Screw, main silencer holder on fuel tank M8
Screw, rear footrest bracket
Screw, front footrest bracket
M8x16
–
M8
M8
–
Loctite® 243™
Screw, spring holder on side stand
bracket
Screw, top triple clamp
Screw, bottom triple clamp
Screw, fork stub
M8
M8
M8
M8
M8
M8
M8
M8
17 Nm (12.5 lbf ft)
12 Nm (8.9 lbf ft)
15 Nm (11.1 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
–
–
–
Loctite® 243™
Screw, steering stem
Screw, handrail
–
Screw, license plate holder, top
Screw, fuel tank, top
Screw, fuel tank, bottom
–
Loctite® 243™
–
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TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
165
Loctite® 243™
Screw, handlebar clamp
Screw, side stand bracket
Screw, connection lever on frame
Remaining nuts, chassis
Remaining screws, chassis
Engine carrying screw
M8
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
30 Nm (22.1 lbf ft)
50 Nm (36.9 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
25 Nm (18.4 lbf ft)
40 Nm (29.5 lbf ft)
45 Nm (33.2 lbf ft)
35 Nm (25.8 lbf ft)
24.5 Nm (18.07 lbf ft)
80 Nm (59 lbf ft)
M8
–
M8
–
M10
–
M10
–
Loctite® 243™
M10
Loctite® 243™
Loctite® 243™
Loctite® 243™
Screw, top shock absorber
Screw, bottom shock absorber
Screw, foot brake pedal
Screw, handlebar support
Screw, engine bearer on frame
Screw, side stand
M10
M10
M10LH
M10
–
M10
–
Loctite® 243™
M10
Lambda probe
M12x1.25
M12x1.75
M14x1.5
M14x1.5
M20x1.5
M20x1.5
M24x1.5
M25x1.5
–
Screw, swingarm pivot
–
Nut, linkage lever to rocker arm
Nut, linkage lever on swingarm
Screw, top steering head
Screw, bottom steering head
Screw, front wheel spindle
Nut, rear wheel spindle
100 Nm (73.8 lbf ft)
100 Nm (73.8 lbf ft)
10 Nm (7.4 lbf ft)
60 Nm (44.3 lbf ft)
40 Nm (29.5 lbf ft)
90 Nm (66.4 lbf ft)
–
–
–
Loctite® 243™
–
–
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SUBSTANCES
166
2S1UBSTANCES
Brake fluid DOT 4 / DOT 5.1
according to
DOT
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.
–
–
Supplier
Castrol
–
RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
–
Brake Fluid DOT 5.1
Coolant
Specification
Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
KTM recommends Motorex® products.
–
Mixture ratio
Antifreeze: −25… −45 °C (−13… −49 °F)
50 % Anti-corrosion/antifreeze
50 % distilled water
Coolant (mixed ready to use)
Antifreeze
−40 °C (−40 °F)
Supplier
Motorex®
–
Anti Freeze
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SUBSTANCES
167
Engine oil (SAE 10W/60)
according to
–
–
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
Supplier
Motorex®
–
Cross Power 4T
Fork oil (SAE 5)
according to
–
Specification
–
Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding prop-
erties. KTM recommends Motorex® products.
Supplier
Motorex®
–
Racing Fork Oil
Hydraulic fluid (15)
according to
ISO VG (15)
–
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SUBSTANCES
168
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.
Supplier
Motorex®
–
Hydraulic Fluid 75
Super unleaded (ROZ 95 / RON 95 / PON 91)
according to
DIN EN 228 (ROZ 95 / RON 95 / PON 91)
–
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AUXILIARY SUBSTANCES
169
2A2UXILIARY SUBSTANCES
Chain cleaner
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Chain Clean 611
Cleaning and polishing materials for metal, rubber and plastic
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Protect & Shine 645
Contact spray
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Accu Contact
High-luster polish for paint
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Moto Polish
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AUXILIARY SUBSTANCES
170
Long-life grease
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Long Therm 2000
Motorcycle cleaner
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Moto Clean 900
Offroad chain spray
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Chain Lube 622
Universal oil spray
Specification
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Joker 440 Universal
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STANDARDS
171
2S3TANDARDS
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. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard
meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos-
ity. The viscosity describes only one property of oil and says nothing about quality.
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INDEX
173
Engine oil
Coolant
Engine oil level
Coolant level
F
Filler cap
D
Filling up
Dust boots
Flasher bulb
E
Engine
Engine characteristic
Engine guard
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INDEX
174
Fork protector
I
Front wheel
K
L
Fuse
M
H
Main fuse
Motorcycle
Handlebar angle
O
Oil filter
Headlight
Oil screen
Headlight mask with headlight
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INDEX
175
Oil screens
S
Seat
OWNER'S MANUAL
P
Parking light bulb
Play in gas Bowden cable
Putting into operation
Spoke tension
R
Rear hub rubber dampers
Steering head bearing play
Rear sprocket / engine sprocket
Rear wheel
T
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INDEX
176
Technical data
Tire air pressure
Tire condition
V
View of vehicle
W
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*3211239en*
3211239en
03/2008 Photo Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
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