OWNER'S MANUAL 2010 690 SMC USA Art. no.
DEAR KTM CUSTOMER 1 Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. DEAR KTM CUSTOMER We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below. Chassis number ( p. 24) Engine number ( p. 25) Key number ( Dealer's stamp p.
DEAR KTM CUSTOMER © 2009 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
TABLE OF CONTENTS TABLE OF CONTENTS MEANS OF REPRESENTATION ............................................... 7 IMPORTANT INFORMATION ................................................... 8 Overview of warning labels................................................. 12 VIEW OF VEHICLE................................................................ 20 View of vehicle, front left side............................................ 20 View of vehicle, rear right side ...........................................
TABLE OF CONTENTS 4 SERVICE PLAN .................................................................... Service schedule .............................................................. MAINTENANCE WORK ON CHASSIS AND ENGINE ................. Jacking up front of motorcycle ........................................... Taking the front from the work stand .................................. Jacking up rear of motorcycle ............................................ Taking the rear from the work stand .............
TABLE OF CONTENTS 5 Removing the seat .......................................................... Mounting the seat .......................................................... Removing the battery ................................................. Installing the battery .................................................. Recharging the battery ............................................... Changing the main fuse ..................................................
TABLE OF CONTENTS AUXILIARY SUBSTANCES................................................... 185 STANDARDS...................................................................... 188 INDEX ...............................................................................
MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding.
IMPORTANT INFORMATION 8 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. Maintenance A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out.
IMPORTANT INFORMATION 9 Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage. Some spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you. You will find the current KTM PowerParts for your vehicle on the KTM website.
IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. 10 Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons.
IMPORTANT INFORMATION 11
IMPORTANT INFORMATION 12 Overview of warning labels 2.
IMPORTANT INFORMATION 1 Type label, Canada 2 Type label, USA 3 Information, emission control 4 Information, noise emission 5 Information, suspension setting 6 Information, chain tension 7 Information, fuel evaporation system 8 Information, putting into operation 13 100341-01 Type label, Canada
IMPORTANT INFORMATION 14 100340-01 Type label, USA 100847-01 Information, emission control
IMPORTANT INFORMATION 15 100846-01 Information, noise emission Information, suspension setting 100344-01
IMPORTANT INFORMATION Information, chain tension 100338-01 Information, fuel evaporation system 100848-01 Information, putting into operation 700210-01 16
IMPORTANT INFORMATION 17 Notes/warnings Pay close attention to the notes/warnings. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
IMPORTANT INFORMATION 18 Owner's manual – It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
IMPORTANT INFORMATION 19 Tampering warning Tampering with noise control system prohibited.
VIEW OF VEHICLE 20 View of vehicle, front left side 3.
VIEW OF VEHICLE 1 Hand brake lever 2 Clutch lever 3 Seat 4 Filler cap 5 Front brake caliper 6 Shift lever 7 Engine number 8 Side stand 9 Footrest 10 Seat release strap 21
VIEW OF VEHICLE 22 View of vehicle, rear right side 3.
VIEW OF VEHICLE 1 Ignition/steering lock 2 Light switch, flasher switch, horn button 3 Rear mirror 4 Combination instrument 5 Emergency OFF switch, electric starter button 6 Throttle grip 7 Rear brake caliper 8 Shock absorber rebound damping 9 Foot brake pedal 10 Engine oil level viewer 23
LOCATION OF SERIAL NUMBERS Chassis number 4.1 The chassis number is stamped on the steering head on the right. 100217-10 Type label 4.2 Type label is located on the upper right frame tube below the seat.
LOCATION OF SERIAL NUMBERS 25 Key number 4.3 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 4.4 The engine number is stamped on the left side of the engine under the engine sprocket.
LOCATION OF SERIAL NUMBERS Fork part number 4.5 The fork part number is stamped on the inner side of the fork stub. 600480-10 Shock absorber part number 4.6 The shock absorber part number is on the right of the shock absorber.
CONTROLS 27 Clutch lever 5.1 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 700542-01 Hand brake lever 5.2 The hand break lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake.
CONTROLS 28 Light switch 5.3 The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on. 100222-10 Turn signal switch 5.4 The turn signal switch is fitted on the left side of the handlebar.
CONTROLS 29 Horn button 5.5 The horn button is fitted on the left side of the handlebar. Possible states • Horn button • Horn button in neutral position pressed – The horn is operated in this position. 100224-10 Emergency OFF switch 5.6 The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.
CONTROLS 30 Electric starter button 5.7 The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button in basic position pressed – In this position, the electric starter is actuated. 100226-10 Ignition/steering lock 5.8 The ignition/steering lock is located in front of the seat.
CONTROLS 31 Combination instrument 5.9 The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. Function buttons Tachometer Indicator lights Display 400832-10 Combination instrument - function buttons 5.10 You can change the display mode with the MODE button . Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2).
CONTROLS 32 Combination instrument - tachometer 5.11 The tachometer shows the engine speed in revolutions per minute. The red marking shows the excess speed range of the engine. 400834-10 Combination instrument - indicator lamps 5.12 The indicator lamps offer additional information about the operating state of the motorcycle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on.
CONTROLS 33 FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. Battery warning lamp lights up red – Voltage in vehicle system too low. Combination instrument - display 5.13 When you switch on the ignition, all display segments light up for a second as a function test. 400836-01 LEnGth Following the display function test, the LEnGth wheel circumference is shown for one second.
CONTROLS 34 Combination instrument - speedometer 5.14 The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 Setting kilometers or miles 5.15 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.
CONTROLS 35 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h. . 400839-01 Combination instrument - time 5.16 The time is shown in area of the display. Info The time has to be reset after the battery is reconnected or when the fuse is changed. 400838-11 Setting the clock 5.
CONTROLS 36 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. . The time display begins to flash. 400838-01 – Press the MODE button to set the hour. – Press the SET button to set the minute. – Keep the MODE button and the SET button pressed simultaneously. The time is set. Combination instrument - display ODO 5.
CONTROLS 37 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. . The TRIP 1 display is set to 0.0. 400840-01 Combination instrument - setting/resetting TRIP 2 5.20 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.
CONTROLS 38 Combination instrument - TRIP F display 5.21 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info Parallel to the TRIP F display, the fuel warning light switches on. 400842-01 Combination instrument - coolant temperature indicator 5.22 The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant.
CONTROLS 39 Opening filler cap 5.23 – 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 5.24 100228-01 – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover.
CONTROLS 40 Handrails 5.25 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 5.26 The seat can be released using strap .
CONTROLS 41 Passenger footrests 5.27 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 5.28 The shift lever is mounted on the left side of the engine.
CONTROLS 42 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 lever 5.29 Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever.
CONTROLS 43 Side stand 5.30 The side stand is coupled with the safety electric starter system - see the riding instructions. Possible states • Side stand folded out – The vehicle can be supported on the side stand. The safety electric starter system is active. • Side stand folded in – This position is mandatory for all journeys. The safety electric starter system is inactive.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 44 Advice on first use 6.1 Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs. Warning Risk of injury Missing or poor protective clothing present an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 45 Info When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully. – Get to know the controls. – Adjust the basic position of clutch lever.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 46 Loading the vehicle 6.3 Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 47 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.
RIDING INSTRUCTIONS Checks before putting into operation 7.1 Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( – Check the engine for loss of oil. – Check the fuel level. – Check the chain tension. ( – Clean the chain. ( – Check the tire condition. ( – Check the tire air pressure. ( – Check the front brake fluid level.
RIDING INSTRUCTIONS 49 Starting 7.2 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
RIDING INSTRUCTIONS 50 Info Do not press the electric starter button until the function test of the combination instrument is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start. Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again. This motorcycle is equipped with a safety start system.
RIDING INSTRUCTIONS 51 Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger must be capable of sitting correctly on the passenger seat.
RIDING INSTRUCTIONS 52 Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of accidents Lack of roadworthiness.
RIDING INSTRUCTIONS 53 – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the 6 forward gears in the figure. The neutral or idle position is between the first and second gears. First gear is used for starting off or for steep inclines.
RIDING INSTRUCTIONS 54 Info From the flashing rhythm, you can derive a two-digit number, the so-called flashing code. The flashing code tells you which component has a fault. Braking 7.5 Warning Danger of accidents If you brake too hard, the wheels can lock. – Adapt your braking to the traffic situation and the road conditions. Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently.
RIDING INSTRUCTIONS 55 Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. – To brake, release the throttle and operate the front and rear brakes simultaneously. – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend.
RIDING INSTRUCTIONS – 56 Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
RIDING INSTRUCTIONS 57 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Warning Environmental hazard Improper handling of fuel is a danger to the environment.
RIDING INSTRUCTIONS 58 – Press the SET button for two seconds. The fuel level warning lamp switches off. TRIP F is set to 0.0 and appears in the previous display mode. Info If you do not press the SET button , the reset takes place automatically after about three minutes.
SERVICE PLAN 59 Service schedule 8.1 K10N K75A K150A K300A Check that the electrical equipment is functioning correctly. • • • • Read out the fault memory using the KTM diagnostics tool. • • • • x • • • • Check the front brake linings. ( p. 90) • • • • Check the rear brake linings. ( p. 100) • • • • • • • • • • • • • • • • • • • • Change the engine oil and filter, clean the oil screens. Check the brake discs. ( x( p. 146) p.
SERVICE PLAN 60 Check the front brake fluid level. ( Bleed the fork legs. ( p. 88) K10N K75A K150A K300A • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • p. 72) Check the steering head bearing play. ( p. 75) • Change the spark plug. Check the valve clearance. • x Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and bellows for cracking, leaks, and correct routing. x Check the antifreeze and coolant level. ( p.
SERVICE PLAN K75A: Every 7,500 km (4,660 mi) or annually K150A: Every 15,000 km (9,321 mi) or every 2 years K300A: Every 30,000 km (18,641 mi) or every 4 years 61
MAINTENANCE WORK ON CHASSIS AND ENGINE 62 Jacking up front of motorcycle 9.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the rear of the motorcycle. ( – Move the handlebar to the straight-ahead position. Align the work stand to the front with the adapters to the fork legs. p. 63) Front work stand (61029055300) Info Always jack up the rear of the motorcycle first. – Jack up the front of the motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 63 Jacking up rear of motorcycle 9.3 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 work stand adapter in the work stand and screw it into the link forks. Work stand adapter (61029055110) Work stand rear (61029055100) – Stand the motorcycle upright, align the work stand to the rear, and jack up the motorcycle. 600492-01 Taking the rear from the work stand 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 64 Fork/shock absorber 9.5 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table . You can find the table on the underside of the seat. 100242-01 These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation.
MAINTENANCE WORK ON CHASSIS AND ENGINE 65 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. Adjusting rebound damping of fork 9.7 Info The hydraulic rebound damping determines the fork rebound behavior. – Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the top end of the fork legs.
MAINTENANCE WORK ON CHASSIS AND ENGINE 66 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. Compression damping of the shock absorber 9.8 The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
MAINTENANCE WORK ON CHASSIS AND ENGINE – 67 Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click. Info Do not loosen nut ! – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed 100245-10 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 68 Turn adjusting screw all the way clockwise using a socket wrench. Info Do not loosen nut ! – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 100246-10 Comfort 1.5 turns Standard 1 turn Sport 0.5 turn Full payload 0.5 turn Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE 69 – Turn adjusting screw clockwise to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 100247-10 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. Measuring the unloaded rear wheel sag 9.12 A 0 400389-10 – Jack up the motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 70 Checking the static sag of the shock absorber 9.13 0 A – Measure distance of rear wheel unloaded. ( – Ask someone to help you by holding the motorcycle upright. – Measure the distance between the rear axle and the fixed point again. – Make a note of the value as measurement . p. 69) Info The static sag is the difference between measurements and . – Check the static sag.
MAINTENANCE WORK ON CHASSIS AND ENGINE 71 Checking the riding sag of the shock absorber 9.14 0 A – Measure distance of rear wheel unloaded. ( – With another person holding the motorcycle, the rider sits on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounces up and down a few times until the rear suspension levels out. – The other person now has to measure the distance between the rear axle and a fixed point.
MAINTENANCE WORK ON CHASSIS AND ENGINE 72 Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly. – Loosen locking ring . – Turn adjusting ring until the spring is no longer under tension. x Hook wrench (T106S) – Measure the overall spring length without a load. – Tension the spring by turning the adjusting ring to the prescribed value.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 73 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. 100844-10 Cleaning the dust boots of the fork legs 9.17 – 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. – Remove the fork protector.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray ( p. 187) – Press the dust boots back into their normal position. – Remove excess oil. – Install the fork protector. ( – Remove the motorcycle from the work stand. – Remove screws and take off clamp. – Remove screws on left fork leg. Remove the fork protector. – Remove the screws on the right fork leg. Remove the fork protector. p.
MAINTENANCE WORK ON CHASSIS AND ENGINE 75 Installing the fork protector 9.19 – Position the fork protection on the left fork leg. Mount and tighten screws . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line and cable harness. Put the clamp on, mount and tighten screws . – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 600633-10 M6 10 Nm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 76 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: – – p. 76) The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. » – Adjusting play of steering head bearing x( Move the handlebar to and fro over the entire steering range. 600636-10 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 77 Guideline Screw, top triple clamp – M8 17 Nm (12.5 lbf ft) Mount and tighten screw . Guideline Screw, steering stem M8 20 Nm (14.8 lbf ft) – Check the steering head bearing play. ( – Remove the motorcycle from the work stand. Loctite® 243™ p. 75) Handlebar position 9.22 On the upper triple clamp, there are 2 holes at a distance to each other. Distance between holes 15 mm (0.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar position 9.23 78 x – 0 1 2 0 Remove the four screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. – Remove the two screws . Remove the handlebar support. – Place the handlebar support in the required position. Fit and tighten the two screws .
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain for dirt 9.24 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 79) 400678-01 Cleaning the chain 9.25 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE 80 Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( – p. 185) After drying, apply chain spray. Chain lube for road use ( p. 185) 400725-01 Checking the chain tension 9.26 Warning Danger of accidents Danger caused by incorrect chain tension.
MAINTENANCE WORK ON CHASSIS AND ENGINE 81 – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upward at a distance from the chain sliding guard and determine the chain tension . Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. » Chain tension 5 mm (0.2 in) Distance to chain sliding guard 30 mm (1.
MAINTENANCE WORK ON CHASSIS AND ENGINE 82 – Check the chain tension. ( – Loosen nut . – Loosen nuts . – Adjust the chain tension by turning adjusting screws on the left and right. p. 80) Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned. Info The upper chain section must be taut.
MAINTENANCE WORK ON CHASSIS AND ENGINE 83 Checking the chain, rear sprocket and engine sprocket 9.28 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. x Info The engine sprocket, rear sprocket and chain should always be replaced together.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 84 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. A Maximum distance at the longest chain section » If distance is greater than the specified measurement: – B 1 2 3 272 mm (10.
MAINTENANCE WORK ON CHASSIS AND ENGINE 85 Guideline Remaining screws, chassis – 10 Nm (7.4 lbf ft) M6 10 Nm (7.4 lbf ft) Check the chain guide for wear. » If the chain guide is worn: – – M6 Change the chain guide. x Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the chain guide.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain guide 9.29 86 x – Remove screws and . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws and . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Condition Number of teeth: ≥ 45 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws and .
MAINTENANCE WORK ON CHASSIS AND ENGINE – 87 Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement . Info Wear reduces the thickness of the brake disc at the contact surface of the brake disc. Brake discs - wear limit 100135-10 » 4.0 mm (0.157 in) Rear 4.5 mm (0.177 in) If the brake disc thickness is less than the specified value: – – Front Replace the brake disc.
MAINTENANCE WORK ON CHASSIS AND ENGINE 88 Checking the front brake fluid level 9.32 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . – Remove cover with membrane . – Add brake fluid to level . 90 Guideline Measurement of Brake fluid DOT 4 / DOT 5.1 ( – 100254-10 5 mm (0.2 in) p. 181) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. Checking the front brake linings 9.34 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 91 Check the brake linings for minimum thickness . ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – – Change the front brake linings. x( p. 91) Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the front brake linings. x( p. 91) 600625-10 Changing the front brake linings 9.35 x Warning Danger of accident Brake system failure.
MAINTENANCE WORK ON CHASSIS AND ENGINE 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. Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles.
MAINTENANCE WORK ON CHASSIS AND ENGINE 93 – 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. – Install the front brake linings. – Add brake fluid level to . x( x( p. 93) p. 94) 100254-11 Guideline Measurement of Brake fluid DOT 4 / DOT 5.
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 . – Remove screws and spacers . Remove the brake caliper. – Clean the brake caliper. 400421-11 100845-10 Installing the front brake linings 9.37 x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE 95 Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings.
MAINTENANCE WORK ON CHASSIS AND ENGINE 96 Guideline Screw, front brake caliper – M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™ Remove the fixation of the hand brake lever. Checking the free travel of foot brake lever 9.38 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the basic position of the foot brake lever 9.39 97 x Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications. – Remove screws on foot brake cylinder .
MAINTENANCE WORK ON CHASSIS AND ENGINE 98 Checking rear brake fluid level 9.40 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Remove screw cap with the washer and membrane . – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( – p. 181) Mount the screw cap with the washer and membrane. Info 100259-10 Clean up overflowed or spilt brake fluid immediately with water. Checking the rear brake linings 9.42 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the brake linings for minimum thickness . ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – – 101 Change the rear brake linings. x( p. 101) Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the rear brake linings. x( p. 101) 100260-10 Changing rear brake linings 9.43 x Warning Danger of accident Brake system failure.
MAINTENANCE WORK ON CHASSIS AND ENGINE 102 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. Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles.
MAINTENANCE WORK ON CHASSIS AND ENGINE 103 – Stand the vehicle upright. – Remove the screw cap with the membrane . – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Make sure that no brake fluid escapes from the brake fluid reservoir. If it does, clean it up. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
MAINTENANCE WORK ON CHASSIS AND ENGINE 104 – 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 pressure point. – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( – p. 181) Mount the screw cap with the membrane. Info 100289-01 Removing front wheel 9.44 Clean up overflowed or spilt brake fluid immediately with water. x – Jack up the rear of the motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 105 – Loosed screw and screw . – Screw out screw about 6 turns, press your hand on the screw to push the wheel spindle out of the fork stub. Remove screw . Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs. – 600622-10 Always lay the wheel down in such a way that the brake disc is not damaged. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. – Remove the spacing sleeves .
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – 106 Replace the wheel bearing. x Clean and grease the shaft seal rings and bearing surface of the distance bushings . Long-life grease ( p. 186) – Insert the distance bushings. – Clean and grease the thread of the wheel spindle and screw . 600626-10 Long-life grease ( – p. 186) Lift the front wheel into the fork, position it, and insert the wheel spindle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 107 – Remove the fixation of the hand brake lever. – Take the front from the work stand. ( – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Fully tighten screws . p. 62) Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) – Take the rear from the work stand. ( p. 63) – Jack up the rear of the motorcycle. ( p.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 108 Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs. – – Always lay the wheel down in such a way that the brake disc is not damaged. Take the rear wheel out of the swing arm. Info 600627-01 Do not operate the foot brake when the rear wheel is removed. Installing the rear wheel 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Replace the wheel bearing. p. 186) Clean and grease the thread of the wheel spindle and nut . Long-life grease ( 600628-10 x Remove the bushing . Clean and grease the working surfaces of the bushing and shaft seal ring . Long-life grease ( – 109 p. 186) – Install the rubber damper and rear sprocket carrier in the rear wheel.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Checking the rear hub rubber dampers 9.48 Take the rear from the work stand. ( 110 p. 63) x Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. – Remove the rear wheel. – Check bearing . » p.
MAINTENANCE WORK ON CHASSIS AND ENGINE – – 111 Change all rubber dampers in the rear hub. Install the rear wheel. x( p. 108) Checking the tire condition 9.49 Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire. – For your own safety, have damaged tires changed immediately. Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the front and rear tires for cuts, run-in objects and other damage. » If the tires exhibit cuts, run-in objects or other damage: – – 112 Change the tires. Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth 400602-10 » If the tread depth is less than the minimum permissible depth: – – ≥ 2 mm (≥ 0.08 in) Change the tires. Check the age of the tires.
MAINTENANCE WORK ON CHASSIS AND ENGINE 113 Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. – Briefly strike each spoke with a screwdriver blade. Info The frequency of the tone is a function of the spoke length and spoke diameter.
MAINTENANCE WORK ON CHASSIS AND ENGINE 114 Tubeless tire system 9.51 This vehicle makes use a tubeless tire system in which a tubeless sealing profile is used instead of the conventional tube. The advantages of the tubeless system lie in the absence of danger from a faulty tube. This greatly reduces the risk of a sudden loss in pressure. The masses and moments of inertia of these wheels are smaller than in conventional spoke wheels with a tube. This results in better handling and riding comfort.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove dust cap. – Check tire air pressure when tires are cold. 115 Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded 400695-01 » Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) If the tire pressure does not meet specifications: – Correct tire pressure. – Mount dust cap. – Pull on strap and raise the rear of the seat at the same time. – Pull back the seat and lift it off.
MAINTENANCE WORK ON CHASSIS AND ENGINE 116 Mounting the seat 9.54 – Hook slot of the seat onto screw , press the rear downward and at the same time push it forward. – Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click. – Finally, check that the seat is correctly mounted. 100276-10 Removing the battery 9.55 x Warning Risk of injury Battery acid and battery gases cause serious cauterization.
MAINTENANCE WORK ON CHASSIS AND ENGINE 117 – Disconnect the negative (minus) cable of the battery. – Pull off the plug connector upwards. – Remove screws . – Pull the retaining bracket of the battery forward and remove it. – Take off the positive pole cover . – Disconnect the positive (plus) cable of the battery. – Push the wiring harness to the side and pull the battery out of the battery rack.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Recharging the battery 9.57 Set the clock. ( 118 p. 35) x Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. – In the event of skin contact, rinse with large amounts of water.
MAINTENANCE WORK ON CHASSIS AND ENGINE 119 Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 120 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 battery. Info Never remove lid . Charge the battery with a maximum of 10% of the capacity specified on the battery housing . – Switch off and disconnect the charger after charging.
MAINTENANCE WORK ON CHASSIS AND ENGINE Info The main fuse protects all power consumers on the vehicle. It is in the starter relay housing, next to the battery. – Switch off all power consumers and switch off the engine. – Remove the seat. ( – Remove protection covers . – Use a needle nose plier to remove a defective main fuse . – Insert the new main fuse. p. 115) 600604-10 Fuse (58011109130) ( p. 173) Info A reserve fuse is located in the starter relay.
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fuses of individual power consumers 9.59 Info The fuse box containing the fuses of individual power consumers is located under the seat. 600604-11 – Switch off all power consumers and the engine. – Remove the seat. ( – Open fuse box cover . p.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 123 Remove the faulty fuse.
MAINTENANCE WORK ON CHASSIS AND ENGINE 124 Tip Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. – Mount the seat. ( – Switch off the ignition by turning the ignition key to position OFF – Remove the seat. ( – Pull the Map‑Select switch and holder upward off of the retaining bracket. – Pull the Map‑Select switch out of the holder. p. 116) Adjusting the engine characteristic 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 125 Turn the adjusting wheel until the desired digit is next to marking . Set the Map‑Select switch to Soft. – Set the adjusting wheel to position 1. Soft – reduced homologated peak performance for better driveability. Set the Map‑Select switch to Advanced. – Set the adjusting wheel to position 2. Advanced – homologated performance with extremely direct responsiveness. 100238-10 Set the Map‑Select switch to Standard.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Cover the fender with a cloth to protect it from damage. – Remove the screws on the left and right. – Tip the headlight mask forward and pull it off upward. – Disconnect the connectors of flashers and headlight . – Put down the headlight mask.
MAINTENANCE WORK ON CHASSIS AND ENGINE 127 Installing the headlight mask with the headlight 9.62 – Connect the connectors of headlight and flasher lights . – Check lighting function. – Remove the cloth from the fender, attach the headlight mask to points on the fender and swing it up to the steering head.
MAINTENANCE WORK ON CHASSIS AND ENGINE 128 – Position groove on counterpiece . – Position brake-hose guide . Mount and tighten screws . 700543-01 Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 100296-10 Changing the headlight bulb 9.63 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. – Remove the headlight mask with the headlight. ( p.
MAINTENANCE WORK ON CHASSIS AND ENGINE 129 – Pull off connector . – Take off rubber cap of the headlight bulb. – Detach spring bar . – Remove headlight bulb . – Insert a new headlight bulb into the headlight housing. 600610-10 Headlight (H4 / socket P43t) ( p. 173) – Fix the headlight bulb in the headlight using the spring bar. – Replace the rubber cap. Attach the connector. – Install the headlight mask with the headlight. ( p. 127) 600611-10 Changing the parking light bulb 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 130 – Remove rubber cap . – 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. 600610-12 Parking light (W5W / socket W2,1x9,5d) ( p. 173) – Insert the bulb socket in the reflector. – Insert the rubber cap. – Install the headlight mask with the headlight. ( p. 127) 600612-10 Changing the rear lamp 9.65 Note Damage to reflector Reduced luminance.
MAINTENANCE WORK ON CHASSIS AND ENGINE 131 – Remove screws and take off the lens. – Press the bulb carefully into the holder, turn it about 30° counterclockwise and remove it from the holder. Info Do not touch the reflector with your fingers and try to avoid contact with oil or grease. 100331-10 – Check parts for damage and wear. Replace damaged or worn parts. – Insert a new bulb and turn it clockwise as far as possible. Brake/tail light (P21/5W / socket BAY15d) ( p.
MAINTENANCE WORK ON CHASSIS AND ENGINE 132 – Remove the screw from the rear of the flasher housing. – Tilt headlamp diffuser forward carefully and take it off. – Press the flasher bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket. Info Do not touch the reflector with your fingers, and keep it free from grease. – 100160-10 Press the new flasher bulb carefully into the socket and turn it clockwise until it stops.
MAINTENANCE WORK ON CHASSIS AND ENGINE 133 The boundary between light and dark must be exactly on the lower mark for a vehicle with a rider. » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 133) Adjusting the headlight range 9.68 – Check the headlight setting. ( – Turn adjusting screw to adjust the headlight range. p.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. – – 100286-10 Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Remove air filter .
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter 9.70 135 x – Clean the air filter box. – Mount air filter . Info The air filter must lie flush against the air filter box along the entire sealing surface . If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. 100287-10 – Hook filter box top into the front of the air filter box and swing down. – Mount and tighten screws .
MAINTENANCE WORK ON CHASSIS AND ENGINE 136 Cooling system 9.71 The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap . The heat expansion causes the surplus coolant to flow into the compensating tank . When the temperature falls, this surplus coolant is sucked back into the cooling system. This permits the specified coolant temperature without causing any malfunctions.
MAINTENANCE WORK ON CHASSIS AND ENGINE 137 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition Engine is cold.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap . – Check antifreeze of coolant. 138 −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – – Correct the antifreeze of the coolant. Check the coolant level in the radiator. The radiator must be completely filled. 100284-10 » If the coolant level does not meet specifications: – Rectify the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p.
MAINTENANCE WORK ON CHASSIS AND ENGINE 139 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition Engine is cold.
MAINTENANCE WORK ON CHASSIS AND ENGINE 140 Alternative 2 Coolant (mixed ready to use) ( – Draining the coolant 9.74 p. 181) Mount the radiator cap. x 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. In case of scalding, rinse immediately with lukewarm water.
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling the cooling system 9.75 141 x Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
MAINTENANCE WORK ON CHASSIS AND ENGINE 142 – Remove the cap from compensating tank and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – 100283-11 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE 143 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw . – When adjusting the clutch lever make sure that there is a minimum clearance to other parts of the vehicle. Guideline Minimum clearance 5 mm (0.2 in) 100282-10 Checking/rectifying the fluid level of the hydraulic clutch 9.77 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid.
MAINTENANCE WORK ON CHASSIS AND ENGINE 144 Checking the play in the throttle cable 9.78 – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play » 3… 5 mm (0.12… 0.2 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. x( p. 145) Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play in the throttle cable 9.79 145 x – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut . – Set the play in the throttle cable by turning the adjusting screw . Guideline Throttle cable play – 3… 5 mm (0.12… 0.2 in) Tighten counter nut . 600631-10 Checking the engine oil level 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the engine oil and filter, cleaning the oil screens 9.81 – – – – – x Drain the engine oil. x ( p. 146) Remove the oil filter. x ( p. 147) Clean the oil screens. x ( p. 149) Install the oil filter. x ( p. 149) Fill up with engine oil. x ( p. 151) 601022-10 Draining the engine oil 9.82 x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves.
MAINTENANCE WORK ON CHASSIS AND ENGINE 147 – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring. – Completely drain the engine oil. – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. 100200-10 Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 100201-01 Removing the oil filter 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Place a suitable container under the engine. – Remove screws . Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) 100202-10 – Remove screws .
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the oil filter 9.84 149 x – Insert oil filters and . – Oil the O-rings of the oil filter cover. Mount oil filter covers and . – Mount and tighten the screws. Guideline Screw, oil filter cover M5 6 Nm (4.4 lbf ft) 100204-10 Cleaning the oil screens 9.85 x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves.
MAINTENANCE WORK ON CHASSIS AND ENGINE 150 – Remove plug with oil screen and the O-rings. – Remove plug with oil screen and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. – Position oil screen with the O-rings. – Mount and tighten plug with the O-ring. 100205-10 100206-10 Guideline Plug, oil screen 100207-10 M20x1.5 15 Nm (11.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen with the O-rings. – Mount and tighten plug with the O-ring. 151 Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 100208-10 Filling up with engine oil 9.86 x Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p.
MAINTENANCE WORK ON CHASSIS AND ENGINE 152 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. – Start the engine and check that it is oil-tight. – Check the engine oil level. ( p. 145) Adding engine oil 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 153 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. – Start the engine and check that it is oil-tight. – Check the engine oil level. ( p.
TROUBLESHOOTING 154 Faults Possible cause Action The engine does not turn when the starter button is pressed Operating error – Carry out the start procedure. ( Battery is discharged – Recharge the battery. Fuse 1, 2, 3 or 4 is blown – Change the fuses of individual power consumers. ( p. 122) Main fuse burned out – Changing the main fuse. ( No ground connection present. – Check the ground connection.
TROUBLESHOOTING 155 Faults Possible cause Action Engine overheats. Radiator fins very dirty – Clean radiator fins. Foam formation in cooling system – Drain the coolant. – Fill the cooling system. FI warning lamp (MIL) lights/flashes x( p. 140) x( Change the radiator hose. x Check the thermostat. x p. 141) Buckled or damaged radiator hose – Thermostat is faulty – Fuse 5 blown – Change the fuses of individual power consumers. ( p.
TROUBLESHOOTING 156 Faults Possible cause Action Time is not (correctly) displayed Fuse 2 blown – Change the fuses of individual power consumers. ( p. 122) – Set the clock. ( Ignition not switched off when vehicle was parked – Recharge the battery. Battery is not charged by alternator – Check the charging voltage. Battery discharged – p. 35) x( p. 118) x Check the quiescent current.
BLINK CODE 157 Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI of warning lamp (MIL) 08 FI warning lamp (MIL) flashes briefly 8x Error level condition Accelerator position sen
BLINK CODE 158 Blink code FI of warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Error level condition Intake air temperature sensor - Input signal too low Intake air temperature sensor - Input signal too high Blink code FI of warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short Error level condition Ambient air pressure sensor - input signal too low Ambient air pressure sensor - input signal too high Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) fl
BLINK CODE 159 Blink code FI of warning lamp (MIL) 25 FI warning lamp (MIL) flashes 2x long, 5x short Error level condition Side stand switch - circuit fault Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Motor drive hall sensor - circuit fault Blink code FI of warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil cylinder 1 - circuit fault Blink code FI of warning lamp (MIL) 41 FI warni
BLINK CODE 160 Blink code FI of warning lamp (MIL) 53 FI warning lamp (MIL) flashes 5x long, 3x short Error level condition Fuel evaporation valve - short circuit to ground or open circuit Fuel evaporation valve - input signal too high Blink code FI of warning lamp (MIL) 54 FI warning lamp (MIL) flashes 5x long, 4x short Error level condition Secondary air valve - short circuit to ground or open circuit Blink code FI of warning lamp (MIL) 58 FI warning lamp (MIL) flashes 5x long, 8x short Error level
BLINK CODE 161 Blink code FI of warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition CAN bus communication error Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition Motor drive voltage (internal) - circuit fault
CLEANING 162 Cleaning the 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, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
CLEANING 163 Warning Danger of accidents Reduced braking efficiency 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 is warm, applying the brakes occasionally. Info The heat produced causes water at inaccessible locations in the engine and the brakes to evaporate. – Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate.
PROTECTIVE TREATMENT FOR WINTER OPERATION 164 Protective treatment 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 the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt. – Clean the motorcycle.
STORAGE 165 Storage 14.1 Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.
STORAGE 166 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. Putting into operation after storage 14.2 – Take the front from the work stand. ( – Take the rear from the work stand. ( – Recharge the battery. – Install the battery. – Set the clock.
TECHNICAL DATA - ENGINE 167 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) Valve play, cold 0.07… 0.13 mm (0.0028… 0.
TECHNICAL DATA - ENGINE 168 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 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 15.1 Engine oil 1.70 l (1.8 qt.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 169 Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite® 243™ Screw, membrane fixation M3 2.5 Nm (1.84 lbf ft) Loctite® 243™ Hose clamp, intake flange M4 1.5 Nm (1.11 lbf ft) – Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™ Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, breather cover on valve cover M5 3 Nm (2.2 lbf ft) Loctite® 243™ Screw, clutch spring M5 6 Nm (4.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 170 Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft) – Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 222 Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, stator bracket M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, thermostat housing M6 10 Nm (7.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 171 Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite® 243™ Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain tensioner M10x1 10 Nm (7.4 lbf ft) – Spark plug M12x1.25 17 Nm (12.5 lbf ft) – Coolant temperature sensor on cylinder head M12x1.5 12 Nm (8.9 lbf ft) – Oil drain plug with magnet M12x1.5 20 Nm (14.
TECHNICAL DATA - CHASSIS 172 Frame Lattice frame made of chrome molybdenum steel tubing, powdercoated 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 brake disc Rear Disc brake with single-piston brake caliper, floating Brake discs - diameter Front 320 mm (12.6 in) Rear 240 mm (9.
TECHNICAL DATA - CHASSIS 173 Steering head angle 63° Wheelbase 1,480±15 mm (58.27±0.59 in) Seat height unloaded 910 mm (35.83 in) Ground clearance unloaded 290 mm (11.42 in) Weight without fuel approx. 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 YTZ10S Battery voltage: 12 V Nominal capacity: 8.
TECHNICAL DATA - CHASSIS License plate lamp 174 W5W / socket W2,1x9,5d 12 V 5W Tires 17.2 Front tire Rear tire 120/70 ZR 17 M/C 58W TL Pirelli Dragon Supercorsa Pro 160/60 ZR 17 M/C 69W TL Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 17.3 Total fuel tank capacity, approx. Fuel reserve, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( 2.5 l (2.6 qt.) p.
TECHNICAL DATA - FORK 175 Fork part number 14.18.7E.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) Spring rate Soft 5.0 N/mm (28.6 lb/in) Medium (standard) 5.2 N/mm (29.7 lb/in) Hard 5.4 N/mm (30.8 lb/in) Air chamber length 100±20 mm (3.94±0.
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7E.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 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 18 mm (0.
TECHNICAL DATA - SHOCK ABSORBER Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 400 mm (15.75 in) Shock absorber fluid Shock absorber oil (SAE 2,5) (50180342S1) ( 177 p.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 178 Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) – Spoke nipple, front wheel M4.5 4 Nm (3 lbf ft) – Bolt, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite® 243™ Remaining screws, chassis M5 4 Nm (3 lbf ft) – Screw, electrical holder M5 3 Nm (2.2 lbf ft) – Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) – Screw, fuel level sensor M5 3 Nm (2.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 179 Screw, magnetic holder on side stand M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, radiator bracket M6 5 Nm (3.7 lbf ft) – Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™ Screw, voltage regulator/rectifier M6 8 Nm (5.9 lbf ft) – Nut, manifold on cylinder head M8 25 Nm (18.4 lbf ft) Copper paste Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 243™ Remaining nuts, chassis M8 30 Nm (22.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 180 Upper fuel tank screw M8 20 Nm (14.8 lbf ft) – Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™ Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) – Remaining screws, chassis M10 45 Nm (33.2 lbf ft) – Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™ Screw, engine bearer on frame M10 45 Nm (33.2 lbf ft) – Screw, foot brake lever M10LH 25 Nm (18.
SUBSTANCES 181 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Guideline – Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming.
SUBSTANCES 182 Engine oil (SAE 10W/60) (00062010035) According to – JASO T903 MA ( – SAE ( – KTM LC4 2007+ p. 188) p. 188) (SAE 10W/60) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Motorex® KTM Cross Power 4T Engine oil (SAE 10W/50) According to – JASO T903 MA ( – SAE ( p. 188) p.
SUBSTANCES 183 Fork oil (SAE 5) According to – SAE ( p. 188) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Racing Fork Oil Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties.
SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91) 184
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 – KTM recommends Motorex® products. Supplier Motorex® – Protect & Shine 645 Contact spray Guideline – KTM recommends Motorex® products.
AUXILIARY SUBSTANCES High-luster polish for paint Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Polish Long-life grease Guideline – KTM recommends Motorex® products. Supplier Motorex® – Fett 2000 Motorcycle cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex® products.
AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex® products.
STANDARDS 188 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, 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.
INDEX 189 rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 101 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 100 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Air filter installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 190 indicator lamps . . . . . . . . . . kilometers or miles, setting . . ODO display . . . . . . . . . . . . . speed display . . . . . . . . . . . . tachometer . . . . . . . . . . . . . time . . . . . . . . . . . . . . . . . . TRIP 1 display, setting/resetting TRIP 2 display, setting/resetting TRIP F display . . . . . . . . . . . . Coolant draining . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 191 Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuse individual power consumers, changing . . . . . . . . . . . . . . 122 H Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX Parking light bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Play in throttle cable adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Protective treatment for winter operation . . . . . . . . . . . . . . . . 164 Putting into operation advice on first use . . . . . . .
INDEX 193 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 T Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Technical data chassis . . . . . . . . . . . . . chassis tightening torques engine . . . . . . . . . . . . . engine tightening torques fork . . . . . .
*3211518en* 3211518en 11/2009 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.
