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

• Page 5: Table Of Contents

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

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

• Page 9: Means Of Representation

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

• Page 10: Important Notes

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

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

• Page 12: Overview Of Warning Labels

  IMPORTANT NOTES Overview of warning labels 100330-10…

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

• Page 20: View Of Vehicle

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

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

• Page 22: View Of Vehicle, Rear Right Side

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

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

• Page 24: Location Of Serial Numbers

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

• Page 25: Key Number

  LOCATION OF SERIAL NUMBERS Key number The key number  can be found on the KEYCODECARD.  Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 100179-10 Engine number The engine number  is stamped on the left side of the engine under the engine sprocket. …

• Page 26: Fork Part Number

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

• Page 27: Operating Elements

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

• Page 28: Light Switch

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

• Page 29: Headlight Flasher Switch

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

• Page 30: Flasher Switch

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

• Page 31: Horn Button

  OPERATING ELEMENTS Horn button The horn button  is fitted on the left side of the handlebar.  Possible states • Horn button  in neutral position pressed – The horn is operated in this position. • Horn button  100224-10 Emergency OFF switch 5.10 The emergency OFF switch …

• Page 32: Electric Starter Button

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

• Page 33: Combination Instrument

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

• Page 34: Combination Instrument — Tachometer

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

• Page 35: Combination Instrument — Display

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

• Page 36: Combination Instrument — Speed Display

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

• Page 37: Combination Instrument — Time

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

• Page 38: Combination Instrument — Odo Display

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

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

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

• Page 40: Combination Instrument — Trip F Display

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

• Page 41: Opening Filler Cap

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

• Page 42: Handrails

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

• Page 43: Passenger Footrests

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

• Page 44: Foot Brake Pedal

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

• Page 45: Side Stand

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

• Page 46: General Tips On Putting Into Operation

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

• Page 47: Running In The Engine

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

• Page 48: Loading The Vehicle

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

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

• Page 50: Riding Instructions

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

• Page 51: Starting

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

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

• Page 53: Starting Up

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

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

• Page 56: Braking

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

• Page 57: Stopping, Parking

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

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

• Page 59: Refueling

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

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

• Page 61: Greasing And Service Table

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

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

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

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

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

• Page 65: Maintenance Work On Chassis And Engine

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

• Page 66: Jacking Up Rear Of Motorcycle

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

• Page 67: Fork/Shock Absorber

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

• Page 68: Adjusting Rebound Damping Of Fork

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

• Page 69: Compression Damping Of Shock Absorber

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

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

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

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

• Page 72: Adjusting Rebound Damping Of The Shock Absorber

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

• Page 73: Cleaning Dust Boots Of Fork Legs

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

• Page 74: Removing The Fork Protector

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

• Page 75: Installing The Fork Protector

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

• Page 76: Adjusting Play Of Steering Head Bearing

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

• Page 77: Handlebar Position

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

• Page 78: Adjusting Handlebar Position

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

• Page 79: Adjusting The Handlebar Angle

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

• Page 80: Checking The Chain Tension

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

• Page 81: Adjusting Chain Tension

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

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

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

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

• Page 84: Checking Chain Wear

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

• Page 85: Adjusting Chain Guide

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

• Page 86: Adjusting Basic Position Of Handbrake Lever

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

• Page 87: Checking Front Brake Fluid Level

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

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

• Page 89: Brake Linings

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

• Page 90: Checking The Front Brake Linings

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

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

• Page 92: Removing Front Brake Linings

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

• Page 93: Mounting Front Brake Linings

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

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

• Page 95: Checking Free Play Of Foot Brake Lever

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

• Page 96: Checking Rear Brake Fluid Level

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

• Page 97: Topping Up Brake Fluid Of Rear Brake

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

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

• Page 99: Checking The Rear Brake Linings

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

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

• Page 102: Removing Front Wheel

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

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

• Page 104: Installing The Front Wheel

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

• Page 105: Removing Rear Wheel

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

• Page 106: Installing The Rear Wheel

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

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

• Page 108: Checking The Rear Hub Rubber Dampers

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

• Page 109: Tire Condition Checking

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

• Page 110: Checking Spoke Tension

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

• Page 111: Checking Tire Air Pressure

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

• Page 112: Removing The Seat

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

• Page 113: Removing The Battery

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

• Page 114: Installing The Battery

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

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

• Page 116: Changing The Main Fuse

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

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

• Page 118: Changing Fuses Of Individual Power Consumers

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

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

• Page 120: Adjusting The Engine Characteristic

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

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

• Page 122: Removing Headlight Mask With Headlight

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

• Page 123: Refitting The Headlight Mask With The Headlight

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

• Page 124: Changing The Headlight Bulb

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

• Page 125: Changing The Parking Light Bulb

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

• Page 126: Changing The Rear Lamp

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

• Page 127: Changing The Flasher Bulb

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

• Page 128: Checking Headlamp Setting

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

• Page 129: Removing The Air Filter

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

• Page 130: Installing The Air Filter

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

• Page 131: Cooling System

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

• Page 132: Checking The Antifreeze And Coolant Level

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

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

• Page 134: Checking The Coolant Level

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

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

• Page 136: Draining Coolant

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

• Page 137: Filling The Cooling System

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

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

• Page 139: Adjusting Basic Position Of Clutch Lever

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

• Page 140: Checking Play In Gas Bowden Cable

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

• Page 141: Adjusting Play In Gas Bowden Cable

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

• Page 142: Checking Engine Oil Level

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

• Page 143: Draining Engine Oil

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

• Page 144: Removing The Oil Filter

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

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

• Page 146: Mounting Oil Filter

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

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

• Page 148: Filling Up With Engine Oil

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

• Page 149: Topping Up Engine Oil

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

• Page 150: Troubleshooting

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

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

• Page 153: Flashing Code

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

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

• Page 156: Cleaning

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

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

• Page 158: Conservation For Winter Operation

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

• Page 159: Storage

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

• Page 160: Putting Into Operation After Storage

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

• Page 161: Technical Data — Engine

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

• Page 162: Capacity — Engine Oil

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

• Page 163: Technical Data — Engine Tightening Torques

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

• Page 164
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES – Screw, engine housing 10 Nm (7.4 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite ® Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, starter motor 10 Nm (7.4 lbf ft) Loctite 243™…
• Page 165
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES Screw, cylinder head Tightening sequence: lubricated with engine oil Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft) –…

• Page 166: Technical Data — Chassis

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

• Page 167: Lighting Equipment

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

• Page 168: Capacity — Fuel

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

• Page 169: Technical Data / Fork

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

• Page 170: Technical Data — Shock Absorber

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

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

• Page 172: Technical Data — Chassis Tightening Torques

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

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

• Page 175: Substances

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

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

• Page 178: Auxiliary Substances

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

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

• Page 180: Standards

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

• Page 181: Index

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

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

1. Manuals
2. Brands
3. KTM Manuals
4. Motorcycle
5. 690 SMC 2008
6. Repair manual

• Page 1
  REPAIR MANUAL 2008 690 SMC EU 690 SMC AUS/UK 690 SMC USA Article no. 3206042en…
• Page 3
  KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

• Page 4: Table Of Contents

  CONTENTS Filling the damper with nitrogen ……..45 CONTENTS MEANS OF REPRESENTATION ……….5 Installing the spring…………45 IMPORTANT NOTES …………6 05/EXHAUST …………..47 LOCATION OF SERIAL NUMBERS ……..7 Removing the exhaust manifold ……..47 Chassis number/type label (690 SMC EU, 690 SMC AUS/UK)…………

• Page 5
  CONTENTS Changing the rear brake fluid………. 80 Measuring axial clearance of crankshaft and balancer shaft …………….112 14/LIGHT SYSTEM, INSTRUMENTS ……..82 Cylinder — Nikasil ® coating ……….112 Setting kilometers or miles ……….82 Checking/measuring the cylinder……..113 Setting the clock …………82 Checking/measuring the piston ……..
• Page 6
  CONTENTS Installing the oil filter ……….144 Page 3 of 10…………… 188 Installing gear position sensor……..145 Page 4 of 10…………… 190 Installing the spacer ………… 145 Page 5 of 10…………… 192 Installing oil screens ………… 146 Page 6 of 10…………… 194 Installing alternator cover ……….

• Page 7: Means Of Representation

  MEANS 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). Identifies a page reference (more information is provided on the specified page). Indicates information with more details or tips.

• Page 8: Important Notes

  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.

• Page 9: Location Of Serial Numbers

  LOCATION OF SERIAL NUMBERS Chassis number/type label (690 SMC EU, 690 SMC AUS/UK) The chassis number is stamped on the right of the steering head.  The type label is on the right of the frame behind the steering head. …

• Page 10: Fork Part Number

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

• Page 11: Motorcycle

  MOTORCYCLE Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the adapter into the rear wheel stand and screw into the swingarm on both sides.

• Page 12: Raising The Motorcycle With The Work Stand

  MOTORCYCLE Raising the motorcycle with the work stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the special tool on the footrest. Work stand adapter (75029036000) ( p.

• Page 13: Starting

  MOTORCYCLE Starting 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.

• Page 14: 01/Fork, Triple Clamp

  01/FORK, TRIPLE CLAMP Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. – 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.

• Page 15: Cleaning The Dust Boots Of The Fork Legs

  01/FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs – Jack up the motorcycle and secure it against falling over. The front wheel is no longer in contact with the ground and the fork legs are no longer under tension. –…

• Page 16: Removing Fork Legs

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

• Page 17: Installing The Fork Legs

  01/FORK, TRIPLE CLAMP – Loosen the screws of the triple clamp. Remove the fork legs from the bottom.  201379-10 Installing the fork legs – Slide the fork legs into the triple clamps on both sides. Info The bleeder screws must face forwards. The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp.

• Page 18: Servicing The Fork

  01/FORK, TRIPLE CLAMP Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean screw and the wheel spindle.

• Page 19: Disassembling The Fork Legs

  01/FORK, TRIPLE CLAMP – Disassemble the fork legs. ( p. 17) – Check the fork legs. ( p. 20) – Assemble the fork legs. ( p. 21) 201240-01 Disassembling the fork legs 5.10 Info These operations are the same on both fork legs. Condition The fork legs have been removed.

• Page 20
  01/FORK, TRIPLE CLAMP – Release the fork leg and clamp it with the axle clamp. Info Use soft jaws. 200661-01 – Push the outer tube downward. – Pull the spring downwards. Mount the special tool on the hexagon. Open-end wrench (T14032) ( p.
• Page 21
  01/FORK, TRIPLE CLAMP – Clamp the fork leg with the axle clamp. – Remove screws of the axle clamp.  200662-01 – Loosen screw of the cartridge and remove it with the sealing ring.  Info Place a container underneath to catch any oil that may run out. 200667-10 –…

• Page 22: Checking The Fork Legs

  01/FORK, TRIPLE CLAMP – Heat up the outer tube in area of the lower sliding bushings.  Guideline 50 °C (122 °F) – Pull the outer tube of the fork off of the inner tube with a jerk. Info The lower sliding bushing must be pulled from its bearing seat.

• Page 23: Assembling The Fork Legs

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

• Page 24
  01/FORK, TRIPLE CLAMP – Grease and push on seal ring  Lubricant (T511) ( p. 206) Info Sealing ring downward, open side upward. – Push on support ring  – Remove the special tool. – Sand the edges of the sliding bushes with 600-grain sandpaper, then clean and grease them.
• Page 25
  01/FORK, TRIPLE CLAMP – Install dust boot  200655-11 – Grease the O-ring of valve of the rebound damping.  Lubricant (T158) ( p. 206) – Mount valve of the rebound damping with the spring on adjusting tube   –…
• Page 26
  01/FORK, TRIPLE CLAMP – Clamp the fork vertically. – Fill it with fork oil. Fork oil per fork 634 ml Fork oil (SAE 5) ( p. 205) (21.44 fl. oz.) Info Pull out and push in the piston rod completely a few times to remove air from the cartridge.

• Page 27: Checking The Steering Head Bearing Play

  01/FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the fork in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 219) – Grease the O-ring of the screw cover. Lubricant (T511) ( p. 206) –…

• Page 28: Adjusting The Steering Head Bearing Play

  01/FORK, TRIPLE CLAMP – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –…

• Page 29: 02/Handlebar, Instruments

  02/HANDLEBAR, INSTRUMENTS Handlebar position On the upper triple clamp, there are 2 holes at a distance to each other.  Distance between holes 15 mm (0.59 in)  The holes on the handlebar support are placed at a distance from the center. …

• Page 30: Adjusting The Play In The Throttle Cable

  28) Adjusting 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 …

• Page 31: 04/Shock Absorber, Swingarm

  04/SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of 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. Info The high-speed setting can be seen during the fast compression of the shock absorber. –…

• Page 32: Adjusting The Rebound Damping Of The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of 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. – Turn adjusting screw clockwise up to the last perceptible click.

• Page 33: Checking The Riding Sag Of The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 30)  – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up 0 0 A and down a few times.

• Page 34: Adjusting The Riding Sag

  04/SHOCK ABSORBER, SWINGARM Adjusting the riding sag – Remove the shock absorber. ( p. 32) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Soft 80 N/mm (457 lb/in) Medium (standard) 85 N/mm (485 lb/in) Hard 90 N/mm (514 lb/in)

• Page 35: Installing The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM – Loosen screw  – Remove screw  – Remove screw  300565-10 – Swing the rear end upwards. – Lift shock absorber upwards and remove.  300566-10 Installing the shock absorber 7.10 – Swing the rear end upwards and insert shock absorber from above.

• Page 36: Servicing The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM – Mount and tighten screw  Guideline Screw, fuel tank, bottom 20 Nm (14.8 lbf ft) – Repeat the operation on the opposite side. 300564-11 – Lift the rear fairing. – Mount and tighten screws  Guideline Screw, main silencer 25 Nm Loctite…

• Page 37: Removing The Spring

  04/SHOCK ABSORBER, SWINGARM Removing the spring 7.12 Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. – Measure and note spring length in preloaded state. – Loosen retaining ring and the adjusting ring with the special tool.

• Page 38: Disassembling The Piston Rod

  04/SHOCK ABSORBER, SWINGARM – Press in seal ring retainer . Remove lock ring   Info Do not scratch the inner surface. 300585-10 – Remove screw . Drain the oil.  300586-10 – Remove the piston rod. Drain the remaining oil. 300587-10 –…

• Page 39: Checking The Damper

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

• Page 40: Removing The Heim Joint

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

• Page 41: Installing The Heim Joint

  04/SHOCK ABSORBER, SWINGARM – Remove lock rings on both sides.  200579-10 – Place special tool underneath and press out the heim joint with special tool   Pressing tool (T1207S) ( p. 217) 200580-10 Installing the heim joint 7.17 –…

• Page 42: Assembling The Piston Rod

  04/SHOCK ABSORBER, SWINGARM Assembling the piston rod 7.18 – Check the damper. ( p. 37) – Clamp the piston rod with the heim joint in a vise. – Mount rubber buffer and locking cap   300543-11 – Position special tool on the piston rod.

• Page 43: Assembling The Damper

  04/SHOCK ABSORBER, SWINGARM Assembling the damper 7.19 – Assemble the piston rod. ( p. 40) – Position membrane  – Mount and tighten membrane cover  – Mount lock ring  300590-10 – Push the spring and sleeve onto the compression damping adjuster. Attach the pis- ton.

• Page 44
  04/SHOCK ABSORBER, SWINGARM – Mount locking cap of the damper cartridge.  – Bleed and fill the damper. ( p. 43) – Fill the damper with nitrogen. ( p. 45) 300594-10 Alternative 1 – Turn the adjusting screw clockwise with a screwdriver up to the last percep- …

• Page 45: Bleeding And Filling The Damper

  04/SHOCK ABSORBER, SWINGARM Bleeding and filling the damper 7.20 Info Before working with the vacuum pump, be sure to read the operating instructions carefully. Completely open the adjusters of the rebound and compression damping. – Remove the screw of the filling port. –…

• Page 46
  04/SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control  lever to Vacuum. Guideline 3 bar The pressure gauge falls to the specified value. 0 bar 200269-10 – When the pressure gauge reaches the specified value, turn the Oil reservoir con- …

• Page 47: Filling The Damper With Nitrogen

  04/SHOCK ABSORBER, SWINGARM – Mount and tighten screw  Guideline Filling port screw M10x1 14 Nm (10.3 lbf ft) 300600-10 Filling the damper with nitrogen 7.21 – Clamp the damper in the vise using soft jaws. – Mount special tool on the damper connector.

• Page 48
  04/SHOCK ABSORBER, SWINGARM Guideline Spring rate Soft 80 N/mm (457 lb/in) Medium (standard) 85 N/mm (485 lb/in) Hard 90 N/mm (514 lb/in) – Tension the spring with the special tool. Spring compressor (T101S) ( p. 217) – Install the spring retainer …

• Page 49: 05/Exhaust

  05/EXHAUST Removing the exhaust manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove the air filter box. ( p. 51) –…

• Page 50: Removing The Main Silencer

  05/EXHAUST – Position the spacer. – Position the manifold at the front with the seals. – Mount and tighten nuts  Guideline Nut, manifold on cylinder 25 Nm Copper paste head (18.4 lbf ft) 300208-11 – Position the exhaust clamp. –…

• Page 51: Installing The Main Silencer

  05/EXHAUST – Loosen screw  302045-10 – Remove screws  – Lift the rear fairing. 302046-10 – Remove screws  – Remove the main silencer. 302047-10 Installing the main silencer – Position the main silencer. – Mount and tighten screws …

• Page 52
  05/EXHAUST – Mount and tighten screws  Guideline Rear fairing screw 2 Nm (1.5 lbf ft) 302046-11…

• Page 53: 06/Air Filter

  06/AIR FILTER Removing the air filter – Remove the seat. ( p. 54) – Remove screws . Remove filter box top   100285-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –…

• Page 54: Installing The Air Filter Box

  06/AIR FILTER – Remove screws  300203-10 – Remove screws  300204-10 – Loosen hose clip  300205-10 – Raise the air filter box at the rear. – Loosen the spring-loaded band-type clamp with the special tool and detach bleed hose …

• Page 55
  06/AIR FILTER – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300204-10 – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300203-11 – Position the voltage regulator. – Mount and tighten screws …

• Page 56: 07/Fuel Tank, Seat, Trim

  07/FUEL TANK, SEAT, TRIM Opening filler cap 10.1 – Lift the cover of the filler cap and insert the ignition key.  – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 100227-10 Closing filler cap 10.2…

• Page 57: Mounting The Side Cover

  07/FUEL TANK, SEAT, TRIM Mounting the side cover 10.6 – Attach the side cover in area and engage it in area   – Mount and tighten screws  Guideline Screw, side cover 2 Nm (1.5 lbf ft) – Repeat the operation on the opposite side. –…

• Page 58: Changing The Fuel Filter

  07/FUEL TANK, SEAT, TRIM – Select «Fuel pump relay function test». – Press «Continue». – In the KTM diagnostics tool, read the information page and start the actuator test with «Continue». Guideline Maximum duration of actuator test 3 min –…

• Page 59
  07/FUEL TANK, SEAT, TRIM – Lift the rear fairing. – Remove screws  300563-10 – Remove screw  – Repeat the operation on the opposite side. – Swing the rear end upwards and secure it. 300564-10 – Remove screws  –…
• Page 60
  07/FUEL TANK, SEAT, TRIM – Mount fuel filter  Arrow points away from the fuel pump.  – Mount hose clamps  Hose clamp pliers (60029057000) ( p. 210) 302608-11 – Position the fuel pump. – Mount and tighten screws …

• Page 61: 09/Front Wheel

  09/FRONT WHEEL Removing front wheel 11.1 – Raise the motorcycle with the rear wheel stand. ( p. 9) – Raise the motorcycle with the front wheel stand. ( p. 9) – Remove screws and spacers   – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.

• Page 62: Checking The Tire Air Pressure

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

• Page 63: Checking The Brake Discs

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

• Page 64: 10/Rear Wheel

  10/REAR WHEEL Removing rear wheel 12.1 – Raise the motorcycle with the rear wheel stand. ( p. 9) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. – Remove nut .

• Page 65: Checking The Chain Tension

  10/REAR WHEEL – Tighten nut  Guideline Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. –…

• Page 66: Adjusting Chain Guide

  10/REAR WHEEL – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left …

• Page 67: Cleaning The Chain

  10/REAR WHEEL – Shift into neutral; pull the lower chain section with specified weight  Guideline Weight of chain wear measurement 15 kg (33 lb.) – Measure distance of 18 chain links in the lower chain section.  Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

• Page 68: Checking The Rear Hub Rubber Dampers

  10/REAR WHEEL – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 206) – After drying, apply chain spray. Chain lube for road use ( p.

• Page 69: Checking The Rim Run-Out

  10/REAR WHEEL » If the spoke tensions differ: – Correct the spoke tension. Checking the rim run-out 12.10 Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload.

• Page 70: 11/Wiring Harness, Battery

  11/WIRING HARNESS, BATTERY Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –…

• Page 71: Connecting The Battery

  – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 72: Checking The Charging Voltage

  11/WIRING HARNESS, BATTERY – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the bat- tery.

• Page 73: Changing Fuses Of Individual Power Consumers

  11/WIRING HARNESS, BATTERY – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 54) – Remove protection covers  600604-10 – Remove a defective main fuse with needle nose pliers.  – Install a new main fuse. Fuse (58011109130) ( p.

• Page 74: Adjusting The Engine Characteristic

  11/WIRING HARNESS, BATTERY 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. – Replace with a spare fuse of the right rating. Fuse (75011088010) ( p.

• Page 75: 13/Brake System

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

• Page 76: Adjusting The Basic Position Of The Hand Brake Lever

  13/BRAKE SYSTEM – Remove the front brake linings. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

• Page 77: Adding Front Brake Fluid

  13/BRAKE SYSTEM Adding front brake fluid 14.5 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.

• Page 78: Checking The Rear Brake Linings

  13/BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.

• Page 79: Changing Rear Brake Linings

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

• Page 80: Checking The Free Travel Of Foot Brake Lever

  13/BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake   caliper support are seated correctly. 400419-10 – Insert the brake pads, insert the bolt and mount the split pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

• Page 81: Checking Rear Brake Fluid Level

  13/BRAKE SYSTEM – Remove screws on foot brake cylinder   – To adjust the basic position of the foot brake lever individually, loosen nut  turn screw accordingly.  Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns.

• Page 82: Changing The Rear Brake Fluid

  13/BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

• Page 83
  13/BRAKE SYSTEM – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( p. 204) – Mount the screw cap with the washer and membrane. – Activate the foot brake lever until there is a firm pressure point. Info Clean up overflowed or spilt brake fluid immediately with water.

• Page 84: 14/Light System, Instruments

  14/LIGHT SYSTEM, INSTRUMENTS Setting kilometers or miles 15.1 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key in the position (690 SMC EU, 690 SMC AUS/UK) (690 SMC USA).

• Page 85: Combination Instrument — Setting/Resetting Trip 2

  14/LIGHT SYSTEM, INSTRUMENTS Combination instrument — setting/resetting TRIP 2 15.4 Info The TRIP 2 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again.

• Page 86: Checking The Headlight Setting

  14/LIGHT SYSTEM, INSTRUMENTS Checking the headlight setting 15.6 – Stand the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –…

• Page 87: Installing The Headlight Mask With The Headlight

  14/LIGHT SYSTEM, INSTRUMENTS Installing the headlight mask with the headlight 15.9 – 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 …

• Page 88: Changing The Headlight Bulb

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

• Page 89
  14/LIGHT SYSTEM, INSTRUMENTS – Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten the screw slightly. – Check the flasher system function.

• Page 90: 30/Engine

  30/ENGINE Removing the engine 16.1 – Raise the motorcycle with the work stand. ( p. 10) – Disconnect the battery. ( p. 68) – Remove the exhaust manifold. ( p. 47) – Drain the coolant. ( p. 149) – Loosen the spring-loaded band-type clamp using the special tool.

• Page 91
  30/ENGINE – Take off the clutch push rod. – Unscrew the electrical connection from the starter motor.  – Remove ground wire from the starter motor.  300216-10 – Loosen hose clip  – Pull off the throttle valve body from the rear. 300217-10 –…

• Page 92: Installing The Engine

  30/ENGINE – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 215) 300222-10 – Remove nut of the lower engine bracket. Remove the screw.  300223-10 – Remove screw of the swingarm pivot.

• Page 93
  30/ENGINE – Install the screw and nut of the lower engine bracket, but do not tighten them  yet. 300223-11 – Remove the floor jack with the special tool. Floor jack attachment (75029055000) ( p. 215) 300222-10 – Position the engine bearer. –…
• Page 94
  30/ENGINE – Reconnect plug connectors of the gear position sensor, the crankshaft position  sensor and the alternator. 300218-11 – Position the throttle valve body. – Position and tighten hose clip  300217-11 – Position the electrical connection on the starter motor. Mount and tighten screw. …
• Page 95
  Remove the motorcycle from the work stand. ( p. 10) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p.

• Page 96: 30/Disassembling The Engine

  30/DISASSEMBLING THE ENGINE Clamping engine into engine work stand 17.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 211) Support for engine work stand (75012001060) ( p. 212) Holder for engine work stand (75012001070) ( p.

• Page 97: Removing The Alternator Cover

  30/DISASSEMBLING THE ENGINE Removing the alternator cover 17.5 – Remove screws . Take off the alternator cover.  – Remove dowels. 300004-10 Removing spacer 17.6 – Remove the spacer of the countershaft.  302124-10 Removing gear position sensor 17.7 – Remove screws.

• Page 98: Removing Thermostat

  30/DISASSEMBLING THE ENGINE – Remove screws. Remove the oil filter cover with the O-ring.  – Pull the oil filter element out of the oil filter case.  Circlip pliers reverse (51012011000) ( p. 208) 300011-10 Removing thermostat 17.9 – Remove screws.

• Page 99: Removing Clutch Cover

  30/DISASSEMBLING THE ENGINE – Remove screw . Take off the water pump wheel   – Take off the water pump cover seal. Info Do not lose the centering pins. 300013-10 – Remove the shaped washer  300014-10 Removing clutch cover 17.12 –…

• Page 100: Removing Timing Chain Tensioner

  30/DISASSEMBLING THE ENGINE Removing timing chain tensioner 17.15 – Remove screw . Take off the seal ring.  – Pull out timing chain tensioner  300017-10 Removing camshafts 17.16 – Remove screw . Take off the camshaft support plate  …

• Page 101: Removing Rotor

  30/DISASSEMBLING THE ENGINE – Remove piston pin retainer  – Remove the piston pin. – Take off the cylinder with the piston. – Push the piston upward out of the cylinder. Info If no other work is required on the cylinder and the piston, you can leave the piston in the cylinder.

• Page 102: Removing Timing Chain And Timing Chain Sprocket

  30/DISASSEMBLING THE ENGINE – Hold the timing chain securing guide tight and pull the timing chain tensioning rail out of the timing chain securing guide.  – Take out the timing chain tensioning rail upwards through the chain shaft. – Remove the timing chain securing guide …

• Page 103
  30/DISASSEMBLING THE ENGINE – Loosen the screws diagonally and remove them with their spring retainers and  clutch springs. – Remove the pressure cap  300052-10 – Remove the pressure piece  – Bend up the lock washer  300053-10 –…

• Page 104: Removing Primary Gear

  30/DISASSEMBLING THE ENGINE Removing primary gear 17.24 – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p. 215) – Screw the special tool on to the primary gear   Extractor (75029021000) ( p. 212) – Hold it using the special tool and pull off the primary gear by turning the screw in. –…

• Page 105: Removing Locking Lever

  30/DISASSEMBLING THE ENGINE Removing locking lever 17.28 – Remove screw  – Take off locking lever with the sleeve and spring.  300069-10 Removing oil pumps 17.29 – Remove the lock washers and normal washers from both oil pumps.  …

• Page 106: Removing Crankshaft And Balancer Shaft

  30/DISASSEMBLING THE ENGINE – Install the special tool with suitable screws.  Extractor (75029048000) ( p. 214) Info Use the 750 drill hole. – Pull off the section of the engine case. Info 300076-10 Do not tension the section of the engine case. The balancer shaft and the main shaft have a stop disk, these usually stick to the bearing.

• Page 107
  30/DISASSEMBLING THE ENGINE – Remove shift forks  Info Ensure that the pins remain in place. 300081-10 – Remove the lock ring and the stop disk.  300082-10 – Pull both transmission shafts out of the bearing seats together.  Info The stop disk of the countershaft usually sticks to the bearing.

• Page 108: 30/Engine — Work On Individual Parts

  30/ENGINE — WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 18.1 – Remove oil jet  – Remove bearing locks of the main shaft bearing , of the countershaft bearing   and of the shift drum bearing …

• Page 109: Work On The Left Section Of The Engine Case

  30/ENGINE — WORK ON INDIVIDUAL PARTS Guideline Oil jet, conrod lubrication 2 Nm Loctite ® 243™ (1.5 lbf ft) – Blow compressed air through all oil holes and check that they are clear. – Position the cover plate . Mount and tighten the screws. …

• Page 110: Work On The Clutch Cover

  30/ENGINE — WORK ON INDIVIDUAL PARTS Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in. –…

• Page 111: Removing Crankshaft Bearing Inner Ring

  30/ENGINE — WORK ON INDIVIDUAL PARTS Removing crankshaft bearing inner ring 18.4 – Fix the crankshaft with special tools in the vise.   Upper part, pressing-out tool (75029047050) ( p. 214) Under part, pressing-out tool (75029047051) ( p. 214) 300135-10 –…

• Page 112
  30/ENGINE — WORK ON INDIVIDUAL PARTS – Press in the new crank pin as far as possible.  Info The crank pin must be pressed in so that oil hole is aligned with oil  hole  If the oil holes are not correctly aligned, the conrod bearing will not be sup- plied with oil.

• Page 113: Checking Crankshaft Run-Out At Bearing Pin

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking crankshaft run-out at bearing pin 18.7 – Position the crankshaft on a roller block. – Rotate the crankshaft slowly. – Check the crankshaft run-out at both bearing pins. ≤ 0.10 mm (≤ 0.0039 in) Crankshaft run-out at bearing pin »…

• Page 114: Measuring Axial Clearance Of Crankshaft And Balancer Shaft

  30/ENGINE — WORK ON INDIVIDUAL PARTS Measuring axial clearance of crankshaft and balancer shaft 18.10 – Insert the crankshaft and balancer shaft in the right engine casing. Info Do not forget the dowels. – Mount the left engine casing. – Mount and tighten the screws.

• Page 115: Checking/Measuring The Cylinder

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking/measuring the cylinder 18.12 – Check the O-ring of the chain adjuster for damage and wear. » If there is damage or wear: – Replace the O-ring. – Check the cylinder bearing surface for damage. »…

• Page 116: Checking Piston Ring End Gap

  30/ENGINE — WORK ON INDIVIDUAL PARTS – Clean the piston ring groove. Use an old piston ring to clean the piston ring groove. – Check the piston rings for damage. » If the piston ring is damaged: – Change the piston ring. Info Mount the piston ring with the marking facing upward.

• Page 117: Checking Piston/Cylinder Mounting Clearance

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking piston/cylinder mounting clearance 18.15 – Check/measure the cylinder. ( p. 113) – Check/measure the piston. ( p. 113) – The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam- eter.

• Page 118: Preparing Timing Chain Tensioner For Installation

  30/ENGINE — WORK ON INDIVIDUAL PARTS – When assembling, first connect the autodecompression spring and then insert the screw through the autodecompression weight. The arm of the autodecompression spring is long enough to pass right  through the autodecompression weight. –…

• Page 119: Checking Timing Assembly

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking timing assembly 18.19 – Clean all parts well. 0 0 1 0 0 5 – Check the timing chain gear / timing chain sprocket for damage and wear.  » If there is damage or wear: –…

• Page 120: Removing Valves

  30/ENGINE — WORK ON INDIVIDUAL PARTS – Remove the small camshaft bearing using the special tool.  Insert for bearing puller (15112018100) ( p. 208) Bearing puller (15112017000) ( p. 208) 300228-10 – Press in the small camshaft bearing as far as possible using the special tool …

• Page 121: Checking Valves

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking valves 18.23 – Check the run-out at the valve plate. Valve — run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate » If the measured value does not equal the specified value: –…

• Page 122: Installing Valves

  30/ENGINE — WORK ON INDIVIDUAL PARTS – Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 210) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head — sealing area distortion »…

• Page 123: Installing Rocker Arm

  30/ENGINE — WORK ON INDIVIDUAL PARTS Installing rocker arm 18.28 – Position the rocker arm and push in the rocker arm shafts   Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards. The small drill hole and the flat surface must point upwards.

• Page 124: Checking The Clutch

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking the clutch 18.30 – Dismantle the antihopping clutch. ( p. 121) 0 0 bk 0 0 4 0 0 5 0 0 6 0 0 2 0 0 9 0 0 b l 0 0 1 0 0 b o 0 0 3…

• Page 125: Preassembling Antihopping Clutch

  30/ENGINE — WORK ON INDIVIDUAL PARTS » If the intermediate discs are not level or are pitted: – Replace all intermediate discs. – Check clutch facing discs for discoloration and scoring.  » If there is discoloration or scoring: – Change all clutch facing discs.

• Page 126: Checking Shift Mechanism

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking shift mechanism 18.32 – Check the shift forks (see ) for damage and wear (visual check).   0 0 A » If there is damage or wear: – 0 0 1 Change the shift fork and the idler/fixed gear pair. 0 0 4 0 0 1 –…

• Page 127: Disassembling The Main Shaft

  30/ENGINE — WORK ON INDIVIDUAL PARTS Disassembling the main shaft 18.34 0303 300127-03 – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws. – Remove stop disk and second-gear fixed gear  …

• Page 128: Checking The Transmission

  30/ENGINE — WORK ON INDIVIDUAL PARTS – Remove stop disk and the first-gear idler gear   – Remove needle bearing and stop disk   – Remove the fifth-gear sliding gear and lock ring   – Remove stop disk and the third-gear idler gear …

• Page 129: Assembling The Main Shaft

  30/ENGINE — WORK ON INDIVIDUAL PARTS » If the fixed gear does not move easily: – Change the fixed gear or the main shaft. – Check fixed gears for smooth operation in the profile of countershaft   » If the fixed gear does not move easily: –…

• Page 130: Assembling Countershaft

  30/ENGINE — WORK ON INDIVIDUAL PARTS Assembling countershaft 18.38 Info Use new lock rings in every repair job. – Oil all parts carefully before assembling. – Check the transmission. ( p. 126) 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –…

• Page 131: Checking Electric Starter Drive

  30/ENGINE — WORK ON INDIVIDUAL PARTS Checking electric starter drive 18.39 300129-01 – Check the teeth and seating of the starter idler gear for damage and wear.  » If there is damage or wear: – Replace the starter idler gear and/or needle bushing. –…

• Page 132: Checking Freewheel

  30/ENGINE — WORK ON INDIVIDUAL PARTS – Compress the expansion ring and remove it, using suitable pliers.  – Take the freewheel out of the primary gear.  300128-10 Checking freewheel 18.41 – Insert the freewheel gear in the primary gear , turning the primary gear clock- …

• Page 133
  30/ENGINE — WORK ON INDIVIDUAL PARTS – Insert the lock ring into the groove with suitable pliers and check that it is  seated correctly. 300127-11…

• Page 134: 30/Assembling The Engine

  30/ASSEMBLING THE ENGINE Installing transmission shafts 19.1 – Clamp the right section of the engine case. Holder for engine work stand (75012001070) ( p. 212) Support for engine work stand (75012001060) ( p. 212) Engine work stand (61229001000) ( p. 211) –…

• Page 135: Installing Crankshaft And Balancer Shaft

  30/ASSEMBLING THE ENGINE Installing crankshaft and balancer shaft 19.2 – Mount the special tool on the alternator side of the crankshaft.  Mounting sleeve (75029080000) ( p. 215) – Mount the special tool on the balancer shaft.  Mounting sleeve (58529005000) ( p.

• Page 136: Installing Oil Pumps

  30/ASSEMBLING THE ENGINE Installing oil pumps 19.4 – Install pins and internal rotors on both oil pump shafts. – Mount external rotors in the engine case. The marking is not visible after mounting. – Mount the oil pump shafts with internal rotors …

• Page 137: Installing Shift Shaft

  30/ASSEMBLING THE ENGINE – Release the locking lever. – Mount and tighten screw  Guideline Screw, shift drum locating 10 Nm Loctite ® 243™ (7.4 lbf ft) 300067-11 Installing shift shaft 19.7 – Slide shift shaft with the washer into the bearing seat. …

• Page 138: Installing Clutch Cage

  30/ASSEMBLING THE ENGINE Installing clutch cage 19.10 – Install supporting plate and needle bearing   300057-10 – Install the clutch cage  Info Turn the clutch cage and oil pump gear wheels backwards and forwards slightly to help them mesh more easily. –…

• Page 139: Installing Crankshaft Position Sensor

  30/ASSEMBLING THE ENGINE – Insert the pressure piece  300061-10 – Place the pressure cap on. – Install and tighten the screws with the spring retainers and clutch springs.  Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) – Remove the special tool.

• Page 140: Installing Timing Chain Rails

  30/ASSEMBLING THE ENGINE Installing timing chain rails 19.13 – Position the timing chain securing guide  Info The cable of the crankshaft position sensor must be laid in the cable chan- nel of the timing chain securing guide. – Thread in the timing chain tensioning rail from above.

• Page 141: Setting Engine To Top Dead Center

  30/ASSEMBLING THE ENGINE Setting engine to top dead center 19.16 – Set the crankshaft to top dead center and lock it with the special tool  Engine blocking screw (77329010000) ( p. 216) 300025-10 Installing piston 19.17 – Shift the joint of the piston rings by 120°. –…

• Page 142: Installing Cylinder Head

  30/ASSEMBLING THE ENGINE – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. Info For clarity, the following steps are illustrated using a disassembled piston. 300036-10 – Position the piston pin retainer. 400366-10 –…

• Page 143: Installing Camshafts

  30/ASSEMBLING THE ENGINE Guideline Cylinder head screw Tightening Lubricated with sequence: engine oil Tighten diag- onally, begin- ning 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)

• Page 144: Checking Valve Clearance

  30/ASSEMBLING THE ENGINE – Remove screw and use the special tool to push the timing chain tensioner  toward the timing chain. Release device for timing chain tensioner (77329051000) ( p. 216) The timing chain tensioner unlocks. – Mount and tighten screw …

• Page 145: Installing Spark Plug

  30/ASSEMBLING THE ENGINE – Remove shims and set them down according to the installation position.  – Correct the shims as indicated by the results of the valve clearance check. – Insert suitable shims. – Position the rocker arms and push in the rocker arm shafts. Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards.

• Page 146: Mounting Water Pump Cover

  30/ASSEMBLING THE ENGINE Mounting water pump cover 19.26 – Push on the shaped washer  300014-11 – Attach the water pump wheel . Mount and tighten screw   Guideline Screw, water pump wheel 10 Nm Loctite ® 243™ (7.4 lbf ft) Loctite ®…

• Page 147: Installing Gear Position Sensor

  30/ASSEMBLING THE ENGINE – Insert the oil filter  – Lubricate the O-ring of the oil filter cover. Install the oil filter cover  – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 300011-11 Installing gear position sensor 19.29…

• Page 148: Installing Oil Screens

  30/ASSEMBLING THE ENGINE Installing oil screens 19.31 – Push the oil screen with O-rings on to a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case.

• Page 149: Installing Starter Motor

  30/ASSEMBLING THE ENGINE – Remove special tool  Engine blocking screw (77329010000) ( p. 216) – Mount and tighten screw  Guideline Plug, crankshaft location 20 Nm (14.8 lbf ft) 300024-11 Installing starter motor 19.33 – Grease O-ring. Mount the starter motor. Long-life grease ( p.

• Page 150: 32/Clutch

  32/CLUTCH Checking/rectifying the fluid level of the hydraulic clutch 20.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –…

• Page 151: 35/Water Pump, Cooling System

  35/WATER PUMP, COOLING SYSTEM Draining coolant 21.1 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 152: Checking The Antifreeze And Coolant Level

  35/WATER PUMP, COOLING SYSTEM – 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.

• Page 153: Checking The Coolant Level

  35/WATER PUMP, COOLING SYSTEM Checking the coolant level 21.4 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 154: 38/Lubrication System

  38/LUBRICATION SYSTEM Oil circuit 22.1 400500-60 Oil screen Force pump Oil filter Oil pressure regulator valve Timing chain tensioner Rocker arm shaft Transmission Clutch Oil jet for piston cooling Oil filter Crankshaft Oil screen Suction pump Transmission Checking the engine oil level 22.2 Info The engine oil level must be checked when the engine is warm.

• Page 155: Checking The Engine Oil Pressure

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

• Page 156: Changing The Engine Oil And Filter, Cleaning The Oil Screens

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

• Page 157: Removing The Oil Filter

  38/LUBRICATION SYSTEM – Thoroughly clean the oil drain plug with a magnet. – Check parts for damage and wear. Replace damaged or worn parts. – Refit the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm…

• Page 158: Cleaning The Oil Screens

  38/LUBRICATION SYSTEM Cleaning the oil screens 22.8 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 159: Filling Up With Engine Oil

  38/LUBRICATION SYSTEM Filling up with engine oil 22.9 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.  Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) (…

• Page 160: 39/Ignition System

  39/IGNITION SYSTEM Alternator — checking the stator winding 23.1 Condition The stator is disconnected. – Reinstall the fuel tank. Stator winding, measurement I — check the resistance – Measure the resistance between the specified points. Stator, connector EN pin 1 – Stator, connector EN pin 2 Alternator ≤…

• Page 161: Ignition Coil — Checking The Secondary Winding

  39/IGNITION SYSTEM Ignition coil — checking the secondary winding 23.3 Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. – Remove the fuel tank. Ignition coil cylinder 1 — check the secondary winding resistance –…

• Page 162: 41/Throttle Valve Body

  – Press «Continue». – Read the information page in the KTM diagnostics tool and use «Continue» to open the «Check the throttle position sensor circuit A position» menu. The motor drive moves the throttle valve to the basic position (completely closed).

• Page 163: Adjusting The Basic Setting Of The Motor Drive

  Select «Adjusting the basic setting of the motor drive». – Press «Continue». – Read the information page in the KTM diagnostics tool and use «Continue» to open the «Adjusting the position of the throttle position sensor in circuit A» menu. 400786-60…

• Page 164
  41/THROTTLE VALVE BODY – Carefully close the throttle valve with your finger and hold it. – Check the voltage value. Info The «Continue» button only appears if the measured value equals the set- point value. Throttle position sensor circuit A Basic position — voltage «THAD»…
• Page 165
  41/THROTTLE VALVE BODY Loctite ® 648™ Info Tighten by hand only, do not use a tool. – Press «Continue». – Open and close the throttle grip fully ten times. The «Continue» button appears. – Press «Continue». – Check the voltage value. Info The «Continue»…

• Page 166: Flashing The Efi Control Unit And/Or The Ept Control Unit

  Fix screws with locking varnish.  – Press «Continue». – Read the information page on the KTM diagnostics tool and, using «Continue», start the «ECU Reset» menu. The control unit is reset. – Complete the procedure with «Continue». – Switch off the ignition by turning the ignition key in the position…

• Page 167: Requesting The Enabling Code

  Select «Change VIN — New identity». 400687-60 – Press «Continue». – Read the information page on the KTM diagnostics tool and, using «Continue», start the coding process. – Overwrite the entry under «Please enter VIN:» with the new chassis number. Info For used control units, the chassis number programmed last is displayed.

• Page 168: Coding The Efi Control Unit And/Or Ept Control Unit

  – Select «Change VIN — New identity». – Press «Continue». – Read the information page on the KTM diagnostics tool and using «Continue» start the coding process. – Under «Please enter VIN:» enter the new VIN. Info For new control units, a sample VIN is displayed.

• Page 169
  41/THROTTLE VALVE BODY – Switch to the main menu. – Select «Show identification». – Compare the old VIN to the new VIN. The new VIN is shown.

• Page 170: Technical Data — Engine

  TECHNICAL DATA — ENGINE Design 1-cylinder 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 171: Technical Data — Tolerance, Wear Limits Of Engine

  TECHNICAL DATA — TOLERANCE, WEAR LIMITS OF ENGINE Camshafts — diameter, bearing pin ≥ 39.95 mm (≥ 1.5728 in) Next to exhaust cam ≥ 17.96 mm (≥ 0.7071 in) Next to inlet cam Valve spring Minimum length (without valve spring cap) 42.3 mm (1.665 in) Valve spring cap — thickness 2.4……

• Page 172
  TECHNICAL DATA — TOLERANCE, WEAR LIMITS OF ENGINE Main shaft axial clearance 0.10… 0.40 mm (0.0039… 0.0157 in) ≤ 0.025 mm (≤ 0.00098 in) Transmission shaft run-out Shift shaft — play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in) Fuel pressure Under every load condition 3.3……

• Page 173: Technical Data — Engine Tightening Torques

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

• Page 174
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug M12x1.25 17 Nm (12.5 lbf ft) –…

• Page 175: Technical Data — Chassis

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

• Page 176: Capacity — Fuel

  120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under: http://www.ktm.com Capacity — fuel 28.2 Total fuel tank capacity, 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

• Page 177: Technical Data — Fork

  TECHNICAL DATA — FORK Fork part number 14.18.7D.12 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks…

• Page 178: Technical Data — Shock Absorber

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

• Page 179: Technical Data — Chassis Tightening Torques

  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, combination instrument holder EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft)

• Page 180
  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES ® Screw, steering stem 20 Nm (14.8 lbf ft) Loctite 243™ – Screw, top triple clamp 17 Nm (12.5 lbf ft) – Upper fuel tank screw 20 Nm (14.8 lbf ft) ® Engine carrying screw 45 Nm (33.2 lbf ft) Loctite 243™…

• Page 181: Cleaning/Protective Treatment

  CLEANING/PROTECTIVE TREATMENT Cleaning the motorcycle 32.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 182: Protective Treatment For Winter Operation

  CLEANING/PROTECTIVE TREATMENT Protective treatment for winter operation 32.2 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres- sive road salt. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt. –…

• Page 183: 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. – Raise the motorcycle with the rear wheel stand. ( p. 9) –…

• Page 184: Service Schedule

  Final check: Check the vehicle for roadworthiness and take a test ride. • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • • Make the service entry in KTM DEALER.NET and in the service record.

• Page 186: Wiring Diagram

  WIRING DIAGRAM Page 1 of 10 35.1 wh-rd rd-bu wh-rd wh-rd wh-rd EM/3 EN/3 bl-rd rd-bu bl-rd ye-rd wh-rd ye-rd 600974-01…

• Page 187
  WIRING DIAGRAM EFI control unit Fuse Battery Generator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator X291 Connector for accessory ground (terminal 31) ACC 1 (not assigned) X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)

• Page 188: 186

  WIRING DIAGRAM Page 2 of 10 35.2 ye-rd bl-rd ye-rd ye-rd ye-rd wh-rd wh-rd wh-rd wh-rd br-gr br-gr wh-rd ye-rd wh-bl wh-bl ye-rd wh-rd ye-rd ye-rd 600975-01…

• Page 189
  WIRING DIAGRAM EFI control unit EPT control unit Fuse Light relay Power relay Combination instrument Ignition/steering lock Emergency OFF switch, electric starter button X295 Diagnostics connector…

• Page 190: 188

  WIRING DIAGRAM Page 3 of 10 35.3 ye-bu ye-bu 600976-01…

• Page 191
  WIRING DIAGRAM Low beam, high beam Fuse Fuse Combination instrument Horn Parking light High beam/low beam switch, horn button, turn signal switch…

• Page 192: 190

  WIRING DIAGRAM Page 4 of 10 35.4 wh-gn ye-bu wh-gn ye-bu wh-gn 600977-01…

• Page 193
  WIRING DIAGRAM Front brake light switch Brake light switch, rear License plate lamp Brake/tail light…

• Page 194: 192

  WIRING DIAGRAM Page 5 of 10 35.5 bl-or ye-bu bl-or 600978-01…

• Page 195
  WIRING DIAGRAM Turn signal relay Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right High beam/low beam switch, horn button, turn signal switch…

• Page 196: 194

  WIRING DIAGRAM Page 6 of 10 35.6 bl-rd bl-rd wh-bl wh-bl 600979-01…

• Page 197
  WIRING DIAGRAM Temperature switch for radiator fan Fuse Fuse Radiator fan X293 Connector for accessory ground (terminal 31) ACC 2 (not assigned) X294 Connector for accessory plus (terminal 15) ACC 2 (not assigned)

• Page 198: 196

  WIRING DIAGRAM Page 7 of 10 35.7 br-pu br-pu br-pu br-pu ye-rd br-pu bl-bu bu-gr bu-gr bl-rd wh-br gn-or wh-bu bl-bu bl-bu ye-rd bu-or ye-rd bl-bu wh-bu gn-or wh-br bl-rd bl-rd br-pu bu-or bu-br bu-br wh-gn wh-gn wh-rd wh-rd wh-or wh-or 600980-01…

• Page 199
  WIRING DIAGRAM EFI control unit EPT control unit Fuse Fuse Fuse Fuel pump Motor drive Combination instrument X295 Diagnostics connector…

• Page 200: 198

  WIRING DIAGRAM Page 8 of 10 35.8 bl-or bl-or rd-gr rd-gr bl-gr bl-gr wh-pu wh-pu gn-rd gn-rd wh-bu wh-bu bu-br bu-br bl-or bl-or 600981-01…

• Page 201
  WIRING DIAGRAM EFI control unit Lambda sensor (cylinder 1) Front wheel speed sensor Fuel evaporation valve (USA version only) Secondary air valve Injector (cylinder 1) Combination instrument Ignition coil (cylinder 1)

• Page 202: 200

  WIRING DIAGRAM Page 9 of 10 35.9 ye-gn ye-gn wh-pk wh-pk ye-or ye-or ye-br ye-br bl-gn bl-gn bl-gn 600982-01…

• Page 203
  WIRING DIAGRAM EFI control unit Throttle position sensor circuit A Intake air temperature sensor Rollover sensor Side stand switch Accelerator position sensor Gear position sensor Combination instrument…

• Page 204: 202

  WIRING DIAGRAM Page 10 of 10 35.10 gn-gr gn-gr wh-ye wh-ye ye-bu ye-bu bl-br bl-br bl-ye bl-ye bu-or bu-or br-rd br-rd 600983-01…

• Page 205
  WIRING DIAGRAM EFI control unit Ambient air pressure sensor Engine coolant temperature sensor (cylinder 1) Fuel level indicator Crankshaft position sensor Clutch switch Manifold absolute pressure sensor (cylinder 1) Combination instrument Map‑Select Switch Black Brown Blue Green Gray Light blue Orange Pink Violet…

• Page 206: Substances

  – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®…

• Page 207
  – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75…

• Page 208: Auxiliary Substances

  AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Strong Cleaning and preserving materials for metal, rubber and plastic Guideline –…

• Page 209
  AUXILIARY SUBSTANCES Lubricant (T152) Guideline – ® KTM recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® Molylube Anti‑Seize Lubricant (T159) Guideline – ® KTM recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® MC‑11 Lubricant (T625) Guideline – ® KTM recommends Molykote products.

• Page 210: Special Tools

  SPECIAL TOOLS Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400125-01 Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58429009000 400073-01…

• Page 211
  SPECIAL TOOLS Tool for inner bearing race Art. no.: 58429037043 400082-01 Mounting sleeve Art. no.: 58529005000 400095-01 Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01…
• Page 212
  SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 400110-01 Hose clamp pliers Art. no.: 60029057000 400142-01 Pliers for spring-loaded band-type clamp Art. no.: 60029057100 400085-01 Rear wheel stand Art. no.: 61029055100 500077-01 Adapter Art. no.: 61029055110 500079-01…
• Page 213
  SPECIAL TOOLS Front wheel stand Art. no.: 61029055300 500078-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Engine work stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01…
• Page 214
  SPECIAL TOOLS Support for engine work stand Art. no.: 75012001060 400153-01 Holder for engine work stand Art. no.: 75012001070 400154-01 Piston assembly ring Art. no.: 75029015102 400156-01 Extractor Art. no.: 75029021000 400157-01 Assembly screws Art. no.: 75029033000 400158-01…
• Page 215
  SPECIAL TOOLS Piston pin lock ring insert Art. no.: 75029035000 400160-01 Work stand adapter Art. no.: 75029036000 400161-01 Push-in drift Art. no.: 75029044010 500163-01 Push-in drift Art. no.: 75029044020 500162-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01…
• Page 216
  SPECIAL TOOLS Upper part, pressing-out tool Art. no.: 75029047050 400186-01 Under part, pressing-out tool Art. no.: 75029047051 400187-01 Extractor Art. no.: 75029048000 400162-01 Clamping plate Art. no.: 75029050000 400163-01 Push-out drift Art. no.: 75029051000 400164-01…
• Page 217
  SPECIAL TOOLS Floor jack attachment Art. no.: 75029055000 400184-01 Mounting sleeve Art. no.: 75029080000 400165-01 Gear segment Art. no.: 75029081000 400068-01 Protection cover Art. no.: 75029090000 400167-01 Holding spanner Art. no.: 75029091000 400168-01…
• Page 218
  SPECIAL TOOLS Spark plug wrench Art. no.: 75029172000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01 Engine blocking screw Art. no.: 77329010000 400177-01 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Valve spring mounting device Art. no.: 78029060000 500165-01…
• Page 219
  SPECIAL TOOLS Spring compressor Art. no.: T101S 300573-10 Hook wrench Art. no.: T106S 301085-01 Art. no.: T120 201235-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01…
• Page 220
  SPECIAL TOOLS Vacuum pump Art. no.: T1240S 200273-10 Pressing tool Art. no.: T129 200584-01 Protecting sleeve Art. no.: T1401 200635-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10…
• Page 221
  SPECIAL TOOLS Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10 Mounting sleeve Art. no.: T1515 300569-10 Filling adapter Art. no.: T1516 300567-10 Hook wrench Art. no.: T157S 200899-10…

• Page 222: Standards

  STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles– the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

• Page 223: Index

  INDEX front brake, changing ……75 INDEX rear brake, adding ……79 Accessories .

• Page 224
  INDEX primary gear, removing ….. . 102 shift shaft, preassembling ….124 rotor, removing .
• Page 225
  INDEX Fuel filter checking ……. . . 27 changing ……. . . 56 Protective treatment for winter operation .
• Page 226
  INDEX Steering head bearing play adjusting ……. . . 26 checking .
• Page 227
  *3206042en* 3206042en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com…

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