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5. 690 DUKE R EU
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• Page 1
  OWNER’S MANUAL 2008 690 DUKE ART. NO. 3211248en…
• Page 3
  KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, as well as printing and other errors.
• Page 4
  Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

• Page 5: Table Of Contents

  CONTENTS Setting the clock ………….. 28 MEANS OF REPRESENTATION ……….6 Combination instrument — ODO display ……. 29 IMPORTANT NOTES …………… 7 Combination instrument — setting/resetting TRIP 1 display..29 VIEW OF VEHICLE…………..12 Combination instrument — setting/resetting TRIP 2 display..30 View of vehicle, front left side……….

• Page 6
  Checking free play of foot brake lever ……… 75 Important maintenance work to be carried out by an Checking rear brake fluid level……….. 75 authorized KTM workshop. (as additional order)….55 Topping up brake fluid of front brake ……76 MAINTENANCE WORK ON CHASSIS AND ENGINE….
• Page 7
  CONTENTS Checking the low beam headlight adjustment….110 STORAGE …………….145 Checking the high beam headlight adjustment ….111 Storage…………….145 Adjusting the light range of the low beam headlight … 112 Putting into operation after storage ……..146 Adjusting the light range of the high beam headlight ..114 TECHNICAL DATA — ENGINE ……….

• Page 8: Means Of Representation

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

• Page 9: Important Notes

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

• Page 10
  IMPORTANT NOTES Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
• Page 11
  IMPORTANT NOTES Warning notes In your own interest, read the specified warning notes. Info Various warning labels are attached to your vehicle. Do not remove any 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.
• Page 12
  IMPORTANT NOTES The owner’s manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

• Page 14: View Of Vehicle

  VIEW OF VEHICLE View of vehicle, front left side 700132-01…

• Page 15
  VIEW OF VEHICLE Combination instrument Rear mirror Clutch lever Seat Handrail Front brake caliper Left fuel tap Shift lever Engine number Side stand…

• Page 16: View Of Vehicle, Rear Right Side

  VIEW OF VEHICLE View of vehicle, rear right side 700133-01…

• Page 17
  VIEW OF VEHICLE Seat lock Light switch, headlight flasher switch, indicator switch, horn Filler cap Emergency OFF switch, electric starter button Hand brake lever Chassis number, type label Rear brake caliper Passenger footrests Map Select Switch Foot brake pedal Engine oil level viewer Right fuel tap…

• Page 18: Location Of Serial Numbers

  LOCATION OF SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the steering head on the right. The type label is located under the chassis number. 500006-01 Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key.

• Page 19: Engine Number

  LOCATION OF SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 700125-01 Fork part number The fork part number is stamped on the inner side of the fork stub. 700126-01…

• Page 20: Shock Absorber Part Number

  LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring toward the rear. 700128-01…

• Page 21: Operating Elements

  OPERATING ELEMENTS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 100114-10 Hand brake lever The hand brake lever is located on the right side of the handlebar and operates the front wheel brake.

• Page 22: Light Switch

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

• Page 23: Flasher Switch

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

• Page 24: Ignition/Steering Lock

  OPERATING ELEMENTS Ignition/steering lock The ignition/steering lock is located in front of the upper triple clamp. Possible states Ignition off In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

• Page 25: Electric Starter Button

  OPERATING ELEMENTS Electric starter button 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. 500022-11 Combination instrument The combination instrument is attached in fromt of the handlebar.

• Page 26: Combination Instrument — Function Buttons

  OPERATING ELEMENTS Combination 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.

• Page 27: Combination Instrument — Control Lamps

  OPERATING ELEMENTS Combination 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 Idling speed indicator lamp lights up green Transmission is in neutral.

• Page 28: Combination Instrument — Display

  OPERATING ELEMENTS Combination instrument — Display When you switch on the ignition, all display segments light up for a second as a function test. 700118-01 LEnGTth Following the display function test, the wheel circumference LEnGth is shown for one sec- ond.

• Page 29: Combination Instrument — Speed Display

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

• Page 30: Combination Instrument — Time

  OPERATING ELEMENTS Turn the ignition key to 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…

• Page 31: Combination Instrument — Odo Display

  OPERATING ELEMENTS Turn the ignition key to 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.

• Page 32: Combination Instrument — Setting/Resetting Trip 2 Display

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

• Page 33: Combination Instrument — Trip F Display

  OPERATING ELEMENTS Combination 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 Combination instrument — coolant temperature indicator The temperature indicator in the display consists of 12 bars.

• Page 34: Opening Filler Cap

  OPERATING ELEMENTS Opening filler cap 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. 500023-10 Closing filler cap Put the filler cap back on and turn the ignition key 90°…

• Page 35: Fuel Taps

  OPERATING ELEMENTS Fuel taps The fuel taps are located on the left/right under the fuel tank. Possible states • Fuel supply closed The knurled screws are turned clockwise as far as possible. The level cannot be compensated and no fuel can flow out of the fuel tank. •…

• Page 36: Seat Lock

  OPERATING ELEMENTS Seat lock The seat lock is located to the right of the seat. You can lock it with the ignition key. 700131-01 OWNER’S MANUAL You can find the owner’s manual in its protective case on the underside of the seat. 500031-10…

• Page 37: Tool Set

  OPERATING ELEMENTS Tool set The tool set is located in the storage compartment under the seat. 700134-01 Passenger footrests The passenger footrests can be folded in and out. Possible states • Passenger footrests folded up For operation without a passenger. •…

• Page 38: Shift Lever

  OPERATING ELEMENTS Shift lever The shift lever is mounted on the left side of the engine. 700137-01 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 700138-01…

• Page 39: Foot Brake Pedal

  OPERATING ELEMENTS Foot brake pedal The footbrake pedal is located in front of the right footrest. The footbrake pedal operates the rear brake. 700136-01 Side stand The side stand is coupled with the safety electric starter system — see the riding instruc- tions.

• Page 40: Tips On Putting Into Operation

  The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling behavior caused by non-approved tires/wheels. Use only tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents Reduced road grip with new tires.

• Page 41: Running In The Engine

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

• Page 42: Loading The Vehicle

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

• Page 43
  TIPS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to slipped baggage. Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. 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.

• Page 44: Riding Instructions

  RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. Check the engine oil level. ( P.

• Page 45: Starting

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

• Page 46
  RIDING INSTRUCTIONS Turn the emergency OFF switch to the position Turn the ignition key to 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.

• Page 47: Starting Up

  RIDING INSTRUCTIONS Starting up Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.

• Page 48
  RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. New tires have a smooth roll surface and therefore cannot provide full road grip.
• Page 49
  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.

• Page 50: Braking

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

• Page 51: Stopping, Parking

  RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by brak- ing.

• Page 52
  RIDING INSTRUCTIONS Always place the vehicle on a firm and even surface. Note Fire hazard Some 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 damage Damage and destruction of components by excessive load.

• Page 53: Refueling

  RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel 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.

• Page 54
  RIDING INSTRUCTIONS Switch off engine. Open the filler cap. ( P. 32) Fill the fuel tank with fuel up to measurement Specification Measurement of 50 mm (1.97 in) Fuel tank content 13.5 l Super unleaded (ROZ 95 / RON 95 / (3.57 US gal) PON 91) ( P.

• Page 55: Greasing And Service Table

  GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A Engine Change engine oil and oil filter, clean oil screens. P. 127) • • • • • • • Check and adjust valve clearance.

• Page 56
  GREASING AND SERVICE TABLE K10N K50A K100A Attachments Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • • Brakes Check the front brake linings. ( P. 74) •…

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

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

• Page 58: Maintenance Work On Chassis And Engine

  MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up front of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over. Always place the vehicle on a firm and even surface. Jack up the rear of the motorcycle. ( P.

• Page 59: Jacking Up Rear Of Motorcycle

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

• Page 60: Fork/Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .

• Page 61: Adjusting Rebound Damping Of Fork

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

• Page 62: Compression Damping Of Shock Absorber

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

• Page 63: Adjusting High-Speed Compression Damping Of The Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE Turn the adjusting screw clockwise with a screwdriver until it stops. Info Do not loosen nut Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Compression damping, low-speed 700144-01 Comfort 20 clicks Standard…

• Page 64: Adjusting Rebound Damping Of The Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE 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 700147-01 Comfort 2 turns…

• Page 65: Bleeding Fork Legs

  MAINTENANCE WORK ON CHASSIS AND ENGINE 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 20 clicks Standard 15 clicks Sport 10 clicks 700148-01 full payload 10 clicks Info…

• Page 66: Checking Chain Dirt

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain dirt Check the chain for coarse dirt accumulation. » If the chain is very dirty: Clean the chain. ( P. 64) Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. Remove oil and grease with a suitable cleaning material.

• Page 67: Checking The Chain Tension

  MAINTENANCE WORK ON CHASSIS AND ENGINE After drying, apply chain spray. Onroad chain spray ( P. 165) Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

• Page 68: Adjusting Chain Tension

  MAINTENANCE WORK ON CHASSIS AND ENGINE Lean the motorcycle on the side stand. Shift gear to neutral. Push the chain upwards near the vertical rib of the swingarm and measure 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.

• Page 69
  MAINTENANCE WORK ON CHASSIS AND ENGINE Lean the motorcycle on the side stand. Shift gear to neutral. Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws left and right. 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…

• Page 70: Checking Rear Sprocket / Engine Sprocket For Wear

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

• Page 71: Checking Chain Wear

  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 700152-01 changed in an authorized KTM workshop, where the necessary tool is available.

• Page 72: Checking Brake Discs

  Warning Danger of accidents Reduced braking due to worn brake discs. Worn brake discs should be replaced immediately in an authorized KTM workshop. Check the thickness of the front and rear brake discs at several places on the disc to…

• Page 73: Adjusting Basic Position Of Handbrake Lever

  Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

• Page 74: Topping Up Brake Fluid Of Front Brake

  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

• Page 75: Brake Linings

  Clean up overflowed or spilt brake fluid immediately with water. 100181-10 Brake linings 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.

• Page 76: Checking The Front 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 linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license.

• Page 77: Checking Free Play Of Foot Brake Lever

  Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

• Page 78: Topping Up Brake Fluid Of Front Brake

  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

• Page 79
  Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info ® KTM recommends DOT 5.1 brake fluid from Motorex . This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands.

• Page 80: Checking Rear Brake Linings

  Checking rear brake linings Warning Danger of accidents Reduced braking due to worn brake linings. Worn brake linings should be replaced immediately in an authorized KTM workshop. Note Danger of accidents Reduced 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.

• Page 81
  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screw and spacing sleeve Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Pull the brake caliper carefully back from the brake disc and hang it to one side. Info Do not pull the handbrake lever when the brake caliper is removed.

• Page 82: Fitting Front Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting front wheel Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Check parts for damage and wear.

• Page 83: Removing Rear Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. Take the front from the work stand. ( P. 56) Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

• Page 84: Fitting Rear Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE Pull the rear wheel and brake caliper support together to the rear until you can swing the brake caliper support to the side. Warning Danger of accidents Reduced braking due to damaged brake discs. Always lay the wheel down in such a way that the brake disc is not damaged.

• Page 85
  MAINTENANCE WORK ON CHASSIS AND ENGINE Check parts for damage and wear. Replace damaged or worn parts. Remove the bushing . Clean and grease the roll surfaces of the bushing and the shaft seal ring Long-life grease ( P. 165) Clean and grease the thread of the wheel spindle and nut Long-life grease ( P.

• Page 86: Checking The Rear Hub Rubber Dampers

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear hub rubber dampers 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.

• Page 87: Tire Condition Checking

  The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling behavior caused by non-approved tires/wheels. Use only tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents Reduced road grip with new tires.

• Page 88: Checking Tire Air Pressure

  MAINTENANCE WORK ON CHASSIS AND ENGINE Examine the tires for cuts, foreign bodies and other damage. Check the depth of the tread. » Info Note local national regulations concerning the minimum tread depth. Minimum tread depth: 2 mm ( 0.08 in) If the minimum tread depth is insufficient: Change the tires.

• Page 89: Removing The Seat

  MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat Insert the ignition key in the seat lock and turn it 45° counterclockwise. Lift up the seat at the rear, pull it back and remove from above. 700131-01 Mounting the seat Suspend the seat on the screw , press the rear downwards and at the same time push it forwards.

• Page 90: Reinstalling The Fuel Tank

  MAINTENANCE WORK ON CHASSIS AND ENGINE Reinstalling the fuel tank Remove the seat. ( P. 87) Remove screw Info The fuel lines do not need to be disconnected. 700159-01 Lay a cloth over the subframe and straighten the steering. Carefully raise the fuel tank and move it backwards. Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat- ing tank (see illustration).

• Page 91: Positioning The Fuel Tank

  MAINTENANCE WORK ON CHASSIS AND ENGINE Positioning the fuel tank Remove the cloth from between the compensating tank and the spoiler. 700160-11 Carefully move the fuel tank forwards and lower it. Mount and tighten screw with bearing sleeve and rubber bushing .

• Page 92: Removing The Battery

  MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the battery Warning Risk of injury Battery acid and battery gases cause serious cauterization. Keep batteries out of the reach of children. Wear suitable protective clothing and goggles. Avoid contact with battery acid and battery gases. Keep the battery away from sparks or open fire.

• Page 93
  MAINTENANCE WORK ON CHASSIS AND ENGINE Fold up positive terminal cover Disconnect the positive (plus) cable of the battery. Detach rubber band 700163-10 Disconnect plug-in connector Remove cover 700164-10 Pull battery up and out of the battery rack. Take the battery out of the frame toward the right.

• Page 94: Installing The Battery

  MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery Push battery from the right into the frame. Position the battery in the battery rack. Info The battery terminals must be at the front. 700165-11 Position cover Connect plug-in connector 700164-11…

• Page 95
  MAINTENANCE WORK ON CHASSIS AND ENGINE Secure the cover with rubber band Connect positive cable . Position positive terminal cover 700163-11 Secure the cover with rubber band Attach the minus cable Position the fuel tank. ( P. 89) Mount the seat. ( P.

• Page 96: Recharging The Battery

  MAINTENANCE WORK ON CHASSIS AND ENGINE Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious cauterization. Keep batteries out of the reach of children. Wear suitable protective clothing and goggles. Avoid contact with battery acid and battery gases. Keep the battery away from sparks or open fire.

• Page 97
  MAINTENANCE WORK ON CHASSIS AND ENGINE Switch off all power-consuming components and switch off the engine. Reinstall the fuel tank. ( P. 88) Disconnect the minus (negative) cable of the battery to avoid damage to the motorcy- cle’s electronics. 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.

• Page 98: Changing The Main Fuse

  MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the main fuse Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. Use only fuses with the prescribed amperage. Never by-pass or repair fuses. 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.

• Page 99: Changing Fuses Of Individual Power Consumers

  Fit a new main fuse. Fuse (58011109130) ( P. 153) 700167-01 Info If the new fuse burns out, contact an authorized KTM workshop. Replace protection cover Position the fuel tank. ( P. 89) Mount the seat. ( P. 87) Set the clock.

• Page 100
  MAINTENANCE WORK ON CHASSIS AND ENGINE Open the fuse box cover 700168-01 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)

• Page 101: Adjusting The Engine Characteristics

  Fuse (75011088015) ( P. 153) Info If the new fuse burns out, contact an authorized KTM workshop. Replace the spare fuse in the fuse box so that it will be available if needed. Close the fuse box cover. Mount the seat. ( P.

• Page 102
  MAINTENANCE WORK ON CHASSIS AND ENGINE Map Select Pull the switch with holder downward off of the retaining bracket. 700196-10 Map Select Position the switch on the outside of the frame. Map Select Pull the switch out of the holder. 700197-01 Turn the adjusting wheel until the desired number is adjacent to marking Info…

• Page 103: Removing Headlight Mask With Headlight

  MAINTENANCE WORK ON CHASSIS AND ENGINE Map Select Set the switch to Performance. Set the adjusting wheel to position 2. Performance Higher performance Map Select Set the switch to Standard. Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9. Standard Map Select Position the switch in the holder.

• Page 104
  MAINTENANCE WORK ON CHASSIS AND ENGINE Swing the headlight mask forward. 700170-01 Disconnect plug-in connector. 700171-01 Remove the screw fitting on both sides. Place the headlight mask to one side. 700172-10…

• Page 105: Refitting The Headlight Mask With The Headlight

  MAINTENANCE WORK ON CHASSIS AND ENGINE Refitting the headlight mask with the headlight Position the headlight mask. Mount and tighten screws on both sides. Specification Screw, headlight mask 5 Nm (3.7 lbf ft) 700172-11 Connect the plug-in connector. 700171-01…

• Page 106: Changing The Low Beam Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE Swing the headlight mask upward. 700170-01 Position the headlight mask. Mount and tighten screws Specification Screw, headlight mask 5 Nm (3.7 lbf ft) Check lighting function. 700169-11 Changing the low beam bulb Note Damage to reflector Keep the glass of the bulb free of grease. After fitting the bulb in the holder, clean the glass with a clean cloth.

• Page 107
  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screws 700169-10 Swing the headlight mask forward. 700170-01 Turn headlight lamp counterclockwise and remove it. Check parts for damage and wear. Replace damaged or worn parts. Position the new headlight bulb in the headlight housing. Low beam/high beam (HB3/P20d) ( P.

• Page 108: Changing The High Beam Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE Swing the headlight mask upward. 700170-01 Position the headlight mask. Mount and tighten screws Specification Screw, headlight mask 5 Nm (3.7 lbf ft) Check lighting function. 700169-12 Changing the high beam bulb Note Damage to reflector Keep the glass of the bulb free of grease. After fitting the bulb in the holder, clean the glass with a clean cloth.

• Page 109
  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screws 700169-10 Swing the headlight mask forward. 700170-01 Turn headlight lamp counterclockwise and remove it. Check parts for damage and wear. Replace damaged or worn parts. Position the new headlight bulb in the headlight housing. Low beam/high beam (HB3/P20d) ( P.

• Page 110: Changing The Parking Light Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE Swing the headlight mask upward. 700170-01 Position the headlight mask. Mount and tighten screws Specification Screw, headlight mask 5 Nm (3.7 lbf ft) Check lighting function. 700169-12 Changing the parking light bulb Note Damage to reflector Keep the glass of the bulb free of grease. After fitting the bulb in the holder, clean the glass with a clean cloth.

• Page 111: Changing The Flasher Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the headlight mask with the headlight. ( P. 101) Set down the headlight mask in front of you as shown in the illustration and carefully tilt the high beam headlight in the direction of the low beam headlight. Turn the bulb holder about 30°…

• Page 112: Checking The Low Beam Headlight Adjustment

  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the screw on the rear of the flasher housing. Carefully swing the diffuser forwards 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 will oil or grease.

• Page 113: Checking The High Beam Headlight Adjustment

  MAINTENANCE WORK ON CHASSIS AND ENGINE Check the low beam headlight adjustment. 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: Adjust the light range of the low beam headlight.

• Page 114: Adjusting The Light Range Of The Low Beam Headlight

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the light range of the low beam headlight On a light-colored wall behind a horizontal area, make a mark as high as the center of the low beam headlight. Make another mark at a distance of under the first mark.

• Page 115
  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjust the light range of the headlight by turning screw Specification The boundary between light and dark must be exactly on the lower mark for a motor- cycle with driver. Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.

• Page 116: Adjusting The Light Range Of The High Beam Headlight

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the light range of the high beam headlight On a light-colored wall behind a horizontal area, make a mark as high as the center of the high beam headlight. Make another mark at a distance of under the first mark.

• Page 117
  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjust the beam distance of the headlight by turning screw Specification The boundary between light and dark must be exactly on the lower mark for a motor- cycle with driver. Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.

• Page 118: Cooling System

  MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system 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 .

• Page 119
  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
• Page 120
  MAINTENANCE WORK ON CHASSIS AND ENGINE Screw off the radiator cap Check antifreeze of coolant. 25… 45 °C ( 13… 49 °F) » If the antifreeze of the cooling liquid does not meet specifications: Correct antifreeze of coolant. Check the coolant level in the radiator. The radiator must be completely full.

• Page 121: Checking The Coolant Level

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the coolant level Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool- ing system to cool down.

• Page 122: Draining Coolant

  MAINTENANCE WORK ON CHASSIS AND ENGINE Screw off the radiator cap and check the coolant level in the radiator. The radiator must be completely full. » If the level of the cooling liquid does not meet specifications: Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( P.

• Page 123: Filling/Bleeding The Cooling System

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

• Page 124
  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove the radiator cap and the bleeder screw Tilt the vehicle slightly to the right. 700182-10 Pour coolant in until it overflows free of bubbles, and then replace the bleeder screw immediately. Alternative 1 Coolant ( P.

• Page 125: Adjusting Basic Position Of Clutch Lever

  MAINTENANCE WORK ON CHASSIS AND ENGINE Switch off the engine and allow it to cool down. After the engine has cooled down, check the coolant level in the radiator again and add more coolant if necessary. Remove the cap of the compensating tank and top up the coolant level up to the MAX marking.

• Page 126: Checking/Correcting Fluid Level Of Hydraulic Clutch

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking/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. Check the fluid level.

• Page 127: Adjusting Play In Gas Bowden Cable

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

• Page 128: Adjusting The Handlebar Angle

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar angle 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.

• Page 129: Changing Engine Oil And Oil Filter, Cleaning Oil Screens

  MAINTENANCE WORK ON CHASSIS AND ENGINE 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. »…

• Page 130
  MAINTENANCE WORK ON CHASSIS AND ENGINE Info Drain the engine oil only when the engine is warm. Stand the motorcycle on its side stand on a horizontal surface. Place a suitable container under the engine. Remove the oil drain plug with the magnet and seal ring.

• Page 131: Removing The Oil Filter

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

• Page 132
  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screws . Remove oil filter cover with O-ring. Pull the oil filter insert out of the oil filter casing. Circlip pliers reverse (51012011000) Completely drain the engine oil. Thoroughly clean parts and sealing area. 700189-01…

• Page 133: Mounting Oil Filter

  MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting oil filter Check parts for damage and wear. Replace damaged or worn parts. Insert oil filter Oil the O-rings of the oil filter cover. Refit the oil filter cover Mount and tighten screws. Specification Screw, oil filter cover 6 Nm (4.4 lbf ft)

• Page 134
  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Problem 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. Remove the plug with the oil screen and O-rings.

• Page 135: Filling Up With Engine Oil

  MAINTENANCE WORK ON CHASSIS AND ENGINE Position oil screen with O-rings. Refit plug with O-ring and tighten it. Specification Plug, oil screen M20x1,5 15 Nm (11.1 lbf ft) 700193-01 Position oil screen with O-rings. Refit plug with O-ring and tighten it. Specification Plug, oil screen M20x1,5…

• Page 136: Topping Up Engine Oil

  MAINTENANCE WORK ON CHASSIS AND ENGINE Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) ( P. 163) Refit plug with O-ring and tighten it. Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.

• Page 137
  MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Start the engine and check that it is oil-tight.

• Page 138: Troubleshooting

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

• Page 139
  Engine has too little power. Fuel filter very dirty Have the fuel filter changed. Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
• Page 140
  TROUBLESHOOTING Faults Possible cause Measure High oil consumption Engine oil level too high Check the engine oil level. ( P. 126) Engine oil too thin (low viscosity) Change engine oil and oil filter, clean oil screens. P. 127) Headlight and parking light not functioning Fuse 7 blown Change the fuses of individual power consumers.

• Page 141: Flashing Code

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

• Page 142
  FLASHING CODE Fault Description Possible cause Measure FI warning lamp (MIL) flashes 2x Malfunction in voltage supply Check the throttle valve con- long, 7x short circuit of throttle valve control trol unit voltage supply. unit FI warning lamp (MIL) flashes 3x Malfunction in injection valve Check the injection long, 3x short…
• Page 143
  FLASHING CODE Fault Description Possible cause Measure FI warning lamp (MIL) flashes 9x Malfunction in CAN bus com- Check CAN bus communica- long, 1x short munication tion. FI warning lamp (MIL) flashes 9x Malfunction in voltage supply Check the throttle valve con- long, 2x short circuit of throttle valve control trol unit.

• Page 144: Cleaning

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

• Page 145
  CLEANING Warning Danger of accidents Reduced braking due to wet or dirty brakes. Clean or dry dirty or wet brakes by riding and braking gently. After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

• Page 146: Conserve For Winter Operation

  CONSERVE FOR WINTER OPERATION. Conservation 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. Clean the motorcycle.

• Page 147: Storage

  0… 35 °C (32… 95 °F) The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. Jack up the rear of the motorcycle. ( P. 57) Jack up the front of the motorcycle. (…

• Page 148: Putting Into Operation After Storage

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

• Page 149: Technical Data — Engine

  TECHNICAL DATA — ENGINE Design 1-cyliner 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11,8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)

• Page 150: Capacity — Engine Oil

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

• Page 151: Technical Data — Engine Tightening Torques

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

• Page 152
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES Screw, engine housing 10 Nm (7.4 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite ® Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) Loctite 243™…
• Page 153
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES Screw, cylinder head Tightening sequence: Engine oil (any) Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft)

• Page 154: Technical Data — Chassis

  TECHNICAL DATA — CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro Lever deflector Suspension travel front 140 mm (5.51 in) Rear 140 mm (5.51 in) Brake system front…

• Page 155: Lighting Equipment

  TECHNICAL DATA — CHASSIS Steering head angle 63.5° Wheelbase 1,472±15 mm (57.95±0.59 in) Seat height unloaded 865 mm (34.06 in) Ground clearance unloaded 155 mm (6.1 in) Weight without fuel 148.5 kg (327.4 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.) Maximum permissible overall weight…

• Page 156: Capacity — Fuel

  160/60 R 17 69 H TL Dunlop Sportmax GPR Alpha 10 Dunlop Sportmax GPR Alpha 10 For further information, see: http://www.ktm.com Capacity — fuel Fuel tank content 13.5 l (3.57 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P.

• Page 157: Technical Data — Fork

  TECHNICAL DATA — FORK Fork part number 14.18.7D.09 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks…

• Page 158: Technical Data — Shock Absorber

  TECHNICAL DATA — SHOCK ABSORBER Shock absorber part number 15.18.7D.09 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport…

• Page 159
  TECHNICAL DATA — SHOCK ABSORBER Weight of rider: 85… 95 kg (187… 209 lb.) 75 N/mm (428 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Riding sag 60… 65 mm (2.36… 2.56 in) Fitted length 376 mm (14.8 in)

• Page 160: Technical Data — Chassis Tightening Torques

  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES Screw, combination instrument 1 Nm (0.7 lbf ft) Screw, combination instrument holder 1 Nm (0.7 lbf ft) ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™ Remaining screws, chassis 4 Nm (3 lbf ft) Screw, pressure regulator 4 Nm (3 lbf ft) ®…

• Page 161
  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES Screw, fuel tap Tightening sequence: tighten in parallel 6 Nm (4.4 lbf ft) ® Screw, magnetic holder on side stand 10 Nm (7.4 lbf ft) Loctite 243™ Screw, voltage regulator/rectifier 8 Nm (5.9 lbf ft) Screw, SLS valve 6 Nm (4.4 lbf ft) Screw, headlight mask…
• Page 162
  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES Screw, manifold on main silencer 25 Nm (18.4 lbf ft) Copper paste Screw, handlebar clamp 20 Nm (14.8 lbf ft) ® Screw, upper subframe 35 Nm (25.8 lbf ft) Loctite 243™ ® Screw, side stand bracket 25 Nm (18.4 lbf ft) Loctite 243™…
• Page 163
  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)

• Page 164: Substances

  Brake fluid DOT 5.1 according to Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex Brake Fluid DOT 5.1…

• Page 165
  Hydraulic fluid (15) according to ISO VG (15) 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…
• Page 166
  SUBSTANCES 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…

• Page 167: Auxiliary Substances

  AUXILIARY SUBSTANCES Chain cleaner Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Chain Clean 611 Onroad chain spray Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Chain Lube 622 Strong Long-life grease Specification ®…

• Page 168
  AUXILIARY SUBSTANCES Cleaning and polishing materials for metal, rubber and plastic Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Protect & Shine 645 High-luster polish for paint Specification ® KTM recommends Motorex products. Supplier ® Motorex ®…

• Page 169: Standards

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

• Page 170: Index

  INDEX cleaning ……..64 Chain tension Antifreeze adjusting .

• Page 171
  INDEX Coolant level opening ……..32 checking .
• Page 172
  INDEX Loading the vehicle ……. 40 Low beam bulb Hand brake lever ……. changing .
• Page 173
  INDEX Parking light bulb Shifting ……..45 changing .
• Page 174
  INDEX Transport ……..8 Troubleshooting .
• Page 175
  *3211248en* 3211248en 12/2007 Photo Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com…

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Read this repair manual carefully and thoroughly before beginning work.

Only use ORIGINAL KTM SPARE PARTS.

The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.

This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

Warranty

The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; otherwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the repair manual.

Spare parts, accessories

Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage.

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. Example: valve spring mounter (59029019000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer’s specific instructions on its usage.

Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts.

Following repairs or servicing, the vehicle must be checked for roadworthiness.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Repair manual

–Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and service your motorcycle.

–This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

Starting4.7

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Caution

Danger of accidents If 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 failure High 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.

–Turn the emergency OFF switch to the position .

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

After you switch on the ignition, you can hear the fuel pump working for about 2 seconds. At the same time, the function test of the combination instrument is run.

–Shift gear to neutral.

The green idling speed indicator lamp N lights up.

– Press the electric starter button .

B00103-10

Info

Do not press the electric starter button until the function test of the combination instrument is finished.

When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again.

This motorcycle is equipped with a safety start system. You can only start the engine if the gearbox is in neutral or if the clutch is pulled when a gear is engaged. If the side stand is folded out and you shift into gear and release the clutch, the engine stops.

–Take the weight off the side stand and swing it back up with your foot as far as it will go.

Starting4.8 the motorcycle to make checks

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Info

Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.

–Turn the emergency OFF switch to the position .

–Shift gear to neutral.

–Switch on the ignition.

–Press the electric starter button .

Info

Do not open the throttle.

B00103-10

Adjusting5.1 the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Adjusting5.2 the rebound damping of the fork

Info

The hydraulic rebound damping determines the fork rebound behavior.

Info

–Position the wheel speed sensor. Mount and tighten screws . Guideline

200710-11

–Position the brake line, wiring harness and clamp.

–Mount and tighten screw . Guideline

200711-11

–Position the splash protector. Mount and tighten screws with the washers. Guideline

200709-10

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

– Clean screw and the wheel spindle.

– Lift the front wheel into the fork, position it, and insert the wheel spindle.

– Mount and tighten screw . Guideline

– Position the brake calipers and check that the brake linings are seated correctly.

– Mount screws with spacers but do not tighten.

– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in the activated position.

The brake caliper straightens.

– Tighten screws . Guideline

Condition

The fork legs have been disassembled.

–Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable.

»If the throttle cable play does not meet specifications:

– Adjust the play in the throttle cable. ( p. 30)

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

–Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.

The idle speed must not change.

»If the idle speed changes:

– Adjust the play in the throttle cable. ( p. 30)

Adjusting6.2 the play in the throttle cable

–Move the handlebar to the straight-ahead position.

–Use the KTM diagnostics tool to set the motor drive to the basic position.

–Loosen counter nut .

–Set the play in the throttle cable by turning the adjusting screw . Guideline

–Tighten counter nut .

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Installing7.5 the shock absorber

– Lift the link fork and insert the shock absorber upwards.

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–Mount screw but do not tighten it yet. Guideline

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Servicing7.6 the shock absorber

Danger

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided.

Condition

The shock absorber has been removed.

–Mount lock rings on both sides.

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–Mount seal rings on both sides and grease them. Lubricant (T158) ( p. 244)

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– Press in both collar sleeves of the heim joint.

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Filling7.16 the damper with nitrogen

–Screw in screw by approx. 2 rotations but do not tighten.

Info

The piston rod is fully extended.

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–Clamp special tool in the vise.

Nitrogen filling tool (T170S1) ( p. 258)

–Connect the special tool to the pressure regulator of the filling cylinder. Filling gas — nitrogen

–Adjust pressure regulator. Guideline

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–Position the damper in the special tool.

The hexagonal part of the tap handle engages in the hexagon socket of the filling port screw.

–Open filler tap .

–Fill the damper for at least 15 seconds. Guideline

Info

Watch the pressure regulator dial.

Make sure that the damper is filled to the specified pressure.

–Close the filling port screw using tap handle .

–Close spigot and take the damper out of the special tool.

–Tighten the filling port screw. Guideline

–Mount the rubber cap of the reservoir.