Art. No. 3206121en: Downloaded From Manuals Search Engine
Art. No. 3206121en: Downloaded From Manuals Search Engine
Art. No. 3206121en: Downloaded From Manuals Search Engine
690 Enduro R EU
690 Enduro R AUS/UK
690 Enduro R USA
Art. no. 3206121en
It is important that you read this repair manual carefully and completely before the start of work.
INTRODUCTION
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
13.7.8 Checking the chain, rear sprocket, engine 17.3.9 Removing thermostat ................................ 114
sprocket, and chain guide............................ 80 17.3.10 Setting engine to ignition top dead center ... 114
13.7.9 Cleaning the chain ...................................... 82 17.3.11 Removing water pump wheel...................... 115
13.7.10 Checking the rear hub rubber dampers.......... 82 17.3.12 Removing clutch cover .............................. 115
14 WIRING HARNESS, BATTERY..................................... 84 17.3.13 Removing spacer and spring ...................... 115
14.1 Removing the battery ...................................... 84 17.3.14 Removing spark plug................................. 116
14.2 Installing the battery ....................................... 84 17.3.15 Removing timing chain tensioner................ 116
14.3 Disconnecting the battery ................................ 84 17.3.16 Removing camshafts ................................. 116
14.4 Connecting the battery .................................... 85 17.3.17 Removing cylinder head ............................ 116
14.5 Recharging the battery .................................... 85 17.3.18 Removing piston ....................................... 117
14.6 Checking the charging voltage .......................... 86 17.3.19 Removing rotor ......................................... 117
14.7 Changing the main fuse ................................... 87 17.3.20 Removing timing chain rails....................... 118
14.8 Changing fuses of individual power 17.3.21 Removing timing chain and timing chain
consumers...................................................... 87 sprocket................................................... 118
14.9 Adjusting the engine characteristic ................... 88 17.3.22 Removing crankshaft position sensor .......... 118
15 BRAKE SYSTEM ........................................................ 90 17.3.23 Removing clutch cage ............................... 119
15.1 Checking the front brake linings ....................... 90 17.3.24 Removing primary gear .............................. 120
15.2 Changing the front brake linings ....................... 90 17.3.25 Removing starter drive............................... 120
15.3 Checking the free travel of the hand brake 17.3.26 Removing shift shaft ................................. 120
lever .............................................................. 92 17.3.27 Removing shift drum locating..................... 120
15.4 Adjusting the free travel of the hand brake 17.3.28 Removing locking lever.............................. 121
lever .............................................................. 92
17.3.29 Removing oil pumps.................................. 121
15.5 Checking the front brake fluid level .................. 92
17.3.30 Removing left engine case ......................... 121
15.6 Adding front brake fluid................................... 93
17.3.31 Removing crankshaft and balancer shaft ..... 122
15.7 Changing the front brake fluid .......................... 93
17.3.32 Removing transmission shafts .................... 122
15.8 Checking the rear brake linings ........................ 94
17.4 Work on individual parts ................................ 123
15.9 Changing the rear brake linings ........................ 95
17.4.1 Work on the right section of the engine
15.10 Checking the free travel of foot brake lever ........ 96 case ........................................................ 123
15.11 Adjusting the basic position of the foot brake 17.4.2 Work on the left section of the engine
lever .............................................................. 96 case ........................................................ 125
15.12 Checking rear brake fluid level ......................... 97 17.4.3 Work on the clutch cover ........................... 126
15.13 Adding rear brake fluid .................................... 97 17.4.4 Removing crankshaft bearing inner ring ...... 127
15.14 Changing the rear brake fluid ........................... 98 17.4.5 Removing balancer shaft drive wheel .......... 127
16 LIGHTING SYSTEM, INSTRUMENTS ......................... 100 17.4.6 Changing the connecting rod, conrod
16.1 Combination instrument ................................ 100 bearing, and crank pin .............................. 127
16.1.1 Setting kilometers or miles ........................ 100 17.4.7 Checking crankshaft run-out at bearing
16.1.2 Setting the clock ...................................... 100 pin .......................................................... 129
16.1.3 Setting/resetting display TRIP 1 ................. 100 17.4.8 Installing balancer shaft drive wheel ........... 129
16.1.4 Setting/resetting display TRIP 2 ................. 100 17.4.9 Installing crankshaft bearing inner ring ....... 129
16.1.5 Setting the wheel circumference ................ 101 17.4.10 Measuring axial clearance of crankshaft
16.2 Checking the headlight setting ....................... 102 and balancer shaft .................................... 130
16.3 Adjusting the headlight range......................... 102 17.4.11 Cylinder - Nikasil® coating ......................... 130
16.4 Removing the headlight mask with the 17.4.12 Checking/measuring the cylinder ................ 131
headlight...................................................... 102 17.4.13 Checking/measuring the piston................... 131
16.5 Installing the headlight mask with the 17.4.14 Checking piston ring end gap ..................... 132
headlight...................................................... 103 17.4.15 Checking piston/cylinder mounting
16.6 Changing the parking light bulb...................... 103 clearance ................................................. 132
16.7 Changing the headlight bulb .......................... 104 17.4.16 Checking oil pumps for wear ...................... 133
16.8 Changing the turn signal bulb ........................ 104 17.4.17 Replacing autodecompressor...................... 133
17 ENGINE .................................................................. 106 17.4.18 Preparing timing chain tensioner for
17.1 Removing the engine..................................... 106 installation ............................................... 134
17.2 Installing the engine...................................... 108 17.4.19 Checking timing assembly ......................... 134
17.3 Engine disassembly....................................... 112 17.4.20 Removing rocker arm ................................ 135
17.3.1 Clamping the engine into the engine 17.4.21 Changing camshaft bearing........................ 135
assembly stand......................................... 112 17.4.22 Removing valves ....................................... 136
17.3.2 Draining the engine oil .............................. 112 17.4.23 Checking valves ........................................ 136
17.3.3 Removing starter motor ............................. 112 17.4.24 Checking valve springs .............................. 137
17.3.4 Removing valve cover ................................ 113 17.4.25 Checking valve spring retainer.................... 137
17.3.5 Removing the alternator cover .................... 113 17.4.26 Checking cylinder head ............................. 137
17.3.6 Removing spacer ...................................... 113 17.4.27 Installing valves ........................................ 138
17.3.7 Removing gear position sensor ................... 113 17.4.28 Installing rocker arm ................................. 139
17.3.8 Removing oil filter .................................... 114 17.4.29 Disassembling the antihopping clutch......... 139
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
101045-10
101046-10
100211-10
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
100179-10
101047-10
101048-10
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Raise the motorcycle using the underride guard under the motorcycle.
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.
800089-10
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Remove the motorcycle from the lift stand and rest it on its side stand.
– Remove the lift stand.
B01290-01
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
300579-10
– Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 219)
300201-10
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
300201-10
300579-10
5.5 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
Info
Do not press the electric starter button until the combination instrument
function check 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 starting system. You can only start
the engine if the transmission is in neutral or if the clutch lever is pulled
when a gear is engaged. If the side stand is folded out and you shift into
gear and release the clutch lever, the engine stops.
– Take the weight off the side stand and swing it back up with your foot as far as it
will go.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
Info
Do not open the throttle.
B00103-10
Info
The hydraulic compression damping determines the fork suspension behavior.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
101071-10 Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Info
The hydraulic rebound damping determines the fork rebound behavior.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
101052-10 Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Info
Carry out this action on both fork legs.
101054-10
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind the dust boots can start to leak.
Warning
B01281-10 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 and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 215)
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
– Position the fork protection. ( p. 14)
– Remove the motorcycle from the lift stand. ( p. 10)
B01282-11
Info
Do not pull the handbrake lever when the brake caliper is removed.
201332-10
Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.
201333-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove screws 4. Take the brake line and wiring harness out of the clamp.
201334-10
– Remove the screws of the wheel speed sensor 5. Hang the wheel speed sensor to
one side.
201335-10
– Loosen screws 6 of the triple clamp on both sides. Remove the fork legs from the
bottom.
201336-10
201337-10
201337-11
– Slide the fork legs into the triple clamps on both sides.
Info
The bleeder screws must face forward.
The topmost milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
The upper fork projection must be the same on both sides.
201335-11
201334-11
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.
201332-11
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws 7.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
201333-11
201488-01
Info
The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
– Note down the present state of rebound damping 1 and compression damping 2.
– Completely open the adjusters of the rebound and compression damping.
201470-10
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 227)
200643-10
Info
The screw cover cannot be removed yet.
200644-12
– Release the fork leg and clamp it with the axle clamp.
Info
Use soft jaws.
201471-10
Info
Preload spacers 4 should be above the special tool.
200646-12
200647-12
200648-12
200649-01
Info
Pull out and push in the piston rod a few times to empty the cartridge.
200650-01
Info
Place a container underneath to catch any oil that may run out.
201472-10
Info
This operation is not needed for further disassembly.
201473-10
200653-01
200735-10
Info
The lock ring has a beveled end where a screwdriver can be applied.
200656-01
Info
The lower sliding bushing 9 must be pulled out of its bearing seat when
doing this.
201474-10
Info
Without using a tool, carefully pull the stack apart by hand.
200658-01
200659-11
Info
The steps are identical for both fork legs.
Preparatory work
– Disassemble the fork legs. ( p. 18)
Main work
– Degrease the piston rod.
– Clamp the piston rod with the special tool.
Clamping stand (T14016S) ( p. 226)
– Remove fluid barrier 1 from the piston rod.
200746-10
201479-10
201480-10
201481-10
Info
This operation is not needed for further disassembly.
200749-12
200697-10
– Remove nut 7.
– Remove shim stack 8 completely.
200698-11
200699-11
200700-10
200701-10
Info
The steps are identical for both fork legs.
Preparatory work
– Disassemble the fork legs. ( p. 18)
Main work
– Clamp the tap compression in a bench vise using soft jaws.
– Remove nut 1.
– Remove the spring.
– Remove washer 2.
201482-10
– Remove piston 3.
– Remove shim stack 4.
201483-10
201484-10
200728-10
200684-10
200685-10
200632-10
200665-10
Info
The steps are identical for both fork legs.
– Mount O-ring 1.
– Lubricate the O-ring.
Lubricant (T158) ( p. 214)
201484-11
Info
Mount the smaller shims below.
Info
201485-10 The side with the largest inside diameter faces upward.
Info
Washer 4 must be free to move against the spring force.
201486-10
– Lock the nut using a punch.
– Extract the tap compression.
Info
The steps are identical for both fork legs.
200715-10
Info
Mount the smaller shims below.
Info
The shim stack must be pressed downward over the collar.
200719-10
Info
The side with the largest inside diameter faces downward.
Info
Align the triangular plate exactly with the piston opening.
200720-10 Info
Mount the nut with the collar facing downward.
200749-11
– Before mounting on the piston, wrap the piston ring around the shaft of a screw-
driver.
– Slide piston rod bk into the cartridge.
201481-11
201487-10
201479-11
Info
The fluid barrier must be tightened as much as possible. Do not use tools.
200746-12
Info
The steps are identical for both fork legs.
Preparatory work
– Check the fork legs. ( p. 23)
– Assemble the cartridge. ( p. 25)
Main work
– Clamp the inner tube with the axle clamp.
Guideline
Use soft jaws.
– Mount special tool.
Protecting sleeve (T1401) ( p. 225)
– Grease and push on dust boot 1.
200669-10
Lubricant (T511) ( p. 214)
Info
Always change the dust boot, lock ring, seal ring, and support ring.
Mount the sealing lip with the spring expander facing downward.
Info
Mount with the sealing lip facing downward with the open side facing
upward.
200670-10
Info
Without using a tool, carefully pull the stack apart by hand.
200671-10
200724-10
Info
The lock ring must engage audibly.
200656-11
200655-11
Info
The fluid barrier must be tightened as much as possible. Do not use tools.
200725-10
– Install the special tool on the cartridge.
Gripping tool (T14026S1) ( p. 226)
Info
The special tool must be used to prevent the adjusting tube from being
lifted and thus to prevent oil from reaching the piston rod.
201475-10
Info
If the cartridge turns as well, press the piston rod slightly to the side.
201478-10
Info
Pull out the piston rod and push back in a number of times to bleed the car-
tridge.
200677-10
201476-10
– Pull the spring down. Mount the special tool on the hexagonal part.
Guideline
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)
201477-10 Info
The screw cover must be screwed to the stop before the piston rod starts
to turn. If the thread of the piston rod is stiff, it must be held to prevent
it from turning. If the screw cover is not screwed to the stop, the rebound
adjustment will not work correctly.
200646-11
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the suspension compo-
nents can cause a serious deterioration in the handling characteris-
tics and overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.
– Turn the adjusting screws to the position they were in before dismantling.
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
– Adjust the steering head bearing play without delay.
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-
aged over time.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 10)
Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
– Adjust the play of the steering head bearing. ( p. 31)
– Move the handlebar to and fro over the entire steering range.
100298-10 The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
» If click positions are noticeable:
– Adjust the play of the steering head bearing. ( p. 31)
– Check the steering head bearing and change if necessary.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 10)
Guideline
Screw, steering stem M8 20 Nm
(14.8 lbf ft)
Finishing work
– Check the steering head bearing play. ( p. 31)
– Remove the motorcycle from the lift stand. ( p. 10)
0
A B
0
Distance B between holes 3.5 mm (0.138 in)
The handlebar can be mounted in 4 different positions. In this way, the handlebar can
be installed in the position most comfortable for the rider.
400271-11
Info
Position the left and right handlebar supports evenly.
Info
Make sure cables and wiring are positioned correctly.
– Position the handlebar clamp. Fit and evenly tighten the four screws 1.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Main work
– Check the routing of the throttle cable.
Both throttle cables must be routed side by side, downward behind the handle-
bars and between the air filter box and frame to the throttle valve body.
» If the throttle cable is not routed as specified:
– Correct the routing of the throttle cable.
202085-10
Finishing work
– Mount the side cover. ( p. 65)
– Mount the seat. ( p. 65)
Danger
400192-10 Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
– Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. ( p. 34)
100280-10
306810-10
306810-11
Caution
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.
– Turn adjusting screw 1 all the way clockwise using a socket wrench.
Info
Do not loosen nut 2!
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Caution
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 low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn the adjusting screw 1 clockwise with a screwdriver up to the last perceptible
click.
Info
Do not loosen nut 2!
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Caution
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
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
A
0 – Note down the value as dimension A.
400988-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 10)
Info
The static sag is the difference between measurements A and B.
B
0
400989-10
A
0 and down a few times.
The rear wheel suspension levels out.
– Another person now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension C.
Info
The riding sag is the difference between measurements A and C.
400990-10
Caution
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
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
Preparatory work
– Raise the motorcycle with the work stand. ( p. 10)
– Remove the seat. ( p. 64)
– Take off the side cover. ( p. 65)
– Remove the shock absorber. ( p. 40)
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen locking ring 1.
– Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (T106S) ( p. 224)
– Measure the overall spring length without a load.
– Tension the spring by turning the adjusting ring 2 to the prescribed value.
Guideline
201271-11 Spring preload 20 mm (0.79 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
201352-10 Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber. ( p. 41)
– Mount the side cover. ( p. 65)
– Mount the seat. ( p. 65)
– Remove the motorcycle from the work stand. ( p. 11)
– Check the static sag of the shock absorber. ( p. 38)
– Adjust the rebound damping of the shock absorber. ( p. 38)
300562-10
300563-10
– Remove screw 3.
– Repeat the operation on the opposite side.
300564-10
– Loosen screw 4.
– Remove screw 5.
– Remove screw 4.
300565-10
300566-10
300566-11
300565-11
300564-11
300563-11
300562-11
Finishing work
– Mount the side cover. ( p. 65)
– Mount the seat. ( p. 65)
– Remove the motorcycle from the work stand. ( p. 11)
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.
Condition
The shock absorber has been removed.
– Remove the spring. ( p. 43)
– Dismantle the damper. ( p. 44)
– Disassemble the piston rod. ( p. 45)
– Check the damper. ( p. 46)
– Remove the heim joint. ( p. 47)
– Install the heim joint. ( p. 48)
– Assemble the piston rod. ( p. 49)
– Assemble the damper. ( p. 50)
– Install the spring. ( p. 55)
201289-01
201271-10
201272-10
201273-10
201274-10
Info
Do not scratch the inner surface.
201276-10
201277-10
201278-10
201279-10
300540-10
– Remove supporting plate 2 and rebound shim stack 3 together with piston 4.
Info
Thread the rebound shim set on a screwdriver and set the parts down
together.
300541-10
Info
Thread the compression shim stack on a screwdriver and set the parts down
together.
200572-11
300542-10
300543-10
300460-01
200577-10
200578-10
200579-10
– Place special tool 5 underneath and press out the heim joint with special tool 6.
Pressing tool (T1207S) ( p. 225)
200580-10
200581-10
200579-11
200578-11
200582-10
300543-11
300548-10
200572-11
– Sand both sides of the piston on a surface plate using 1200-grit sandpaper.
– Clean the piston.
– Assemble the piston.
Guideline
View A Piston from above
View B Piston from below
201270-10
– Mount the rebound shim stack 7 with the smaller shims facing upward.
– Install supporting plate 8.
300541-11
300540-11
201279-11
201277-11
201288-10
201278-11
– Install the seal ring bearer 4 and push it under the ring groove.
– Mount lock ring 5.
Info
Do not scratch the inner surface.
– Pull out the piston rod so that the seal ring retainer rests against the lock ring.
201276-10
201275-10
Alternative 1
– Turn adjusting screw 7 clockwise with a screwdriver up to the last perceptible
click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
Comfort 20 clicks
201287-10 Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
– Turn adjusting screw 8 all the way clockwise using a socket wrench.
– Turn back counterclockwise the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Full payload 1 turn
– Turn adjusting screw 9 clockwise up to the last perceptible click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the suspension compo-
nents can cause a serious deterioration in the handling characteris-
tics and overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.
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.
Info
Tighten only hand-tight, without the use of tools.
201286-10 – Clamp the damper with soft jaws or hold it as shown in the photo.
Info
Clamp the damper only lightly.
The filling port must be at the highest point.
The piston rod slides in and out during filling - do not hold it tight with your
hand!
200271-10
The vacuum gauge 8 falls to the specified value.
4 mbar
– Measure distance A between the floating piston and reservoir hole with the special
tool.
Depth micrometer (T107S) ( p. 224)
The floating piston is positioned all the way at the bottom.
201285-10
– When the vacuum pressure gauge reaches the specified value, turn the Oil reser-
voir control lever 5 to Equalize pressure.
Guideline
4 mbar
The pressure gauge rises to the specified value.
0 bar
200267-10
– When the pressure gauge reaches the specified value, turn the Damper control
lever 4 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
The pressure gauge rises to the specified value.
3 bar
200268-10
– When the pressure gauge reaches the specified value, turn the Damper 4 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 5 con-
trol lever to Vacuum.
Guideline
0 bar
The vacuum gauge falls to the specified value.
4 mbar
200270-10
– When the vacuum pressure gauge reaches the specified value, turn the Oil reser-
voir control lever 5 to Equalize Pressure.
Guideline
4 mbar
The pressure gauge falls to the specified value.
0 bar
200267-10
– When the pressure gauge reaches the specified value, turn the Damper control
lever 4 to Pressure.
Guideline
0 bar
Oil is pumped into the damper.
The pressure gauge rises to the specified value.
3 bar
200268-10
– When the pressure gauge reaches the specified value, turn the Damper 4 control
lever to Vacuum.
Guideline
3 bar
The pressure gauge falls to the specified value.
0 bar
– When the pressure gauge reaches the specified value, operate the On/Off switch.
200269-10 Guideline
0 bar
The vacuum pump is switched off.
– Slide O-ring B to the end of the special tool by the specified value (distance A
minus specified value).
Guideline
10 mm
Info
Hold the damper so that the filling port is at the highest point.
Info
The piston rod is fully extended.
201282-10
Info
Watch the pressure regulator dial.
Make sure that the damper is filled to the specified pressure.
201271-11
Alternative 2
Warning
Danger of accidents Modifications to the suspension settings can seri-
ously alter the vehicle's ride behavior.
– Extreme modifications to the adjustment of the suspension compo-
nents can cause a serious deterioration in the handling characteris-
tics and overload some components.
– Only make adjustments within the recommended range.
– After making adjustments, ride slowly at first to get the feel of the
new ride behavior.
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.
Preparatory work
– Remove the seat. ( p. 64)
– Take off the side cover. ( p. 65)
– Remove the air filter box. ( p. 61)
Main work
– Unplug connector 1 of the lambda sensor. Open the cable binder.
300210-10
– Remove screws 2.
– Remove the heat shield.
300207-10
Info
Do not misplace the spacers.
300208-10
– Loosen screw 4.
– Remove the manifold.
300209-10
300209-11
300208-11
300209-12
– Plug in the connector of the lambda sensor 3. Secure the cable with the cable
binders.
300210-11
300207-11
Finishing work
– Install the air filter box. ( p. 62)
– Mount the side cover. ( p. 65)
– Mount the seat. ( p. 65)
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 screws 1.
– Take off the exhaust heat shield.
302044-10
– Loosen screw 2.
302045-10
– Remove screws 3.
– Lift the rear fairing.
302046-10
– Remove screws 4.
– Remove the main silencer.
302047-10
302047-11
302045-10
302044-11
302046-11
100285-10
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.
100286-10
Info
The air filter must lie flush against the air filter box along the entire sealing
surface A.
If the air filter is not correctly mounted, dust and dirt can enter the engine
and cause damage.
100287-10
– Hook air filter box top 2 into the front of the air filter box and swing down.
– Mount and tighten screws 3.
Guideline
Screw, air filter box top M6 2 Nm (1.5 lbf ft)
100285-11
Finishing work
– Mount the seat. ( p. 65)
Main work
– Remove screws 1.
– Take off the voltage regulator and hang it to the side in a de-energized state.
– Detach and expose hose 2.
300202-10
– Remove screws 3.
300203-10
– Remove screws 4.
300204-10
300205-10
300206-10
300206-11
300205-11
300204-10
300203-11
300202-11
Finishing work
– Mount the side cover. ( p. 65)
– Mount the seat. ( p. 65)
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Lift the cover of filler cap 1 and insert the ignition key.
– Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
The filler cap has a fuel tank breather.
100227-10
101070-01
101049-10
800096-10
300198-10
300198-11
Finishing work
– Mount the seat. ( p. 65)
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Condition
The fuel tank is completely full.
Ensure that the battery voltage does not drop below 12.5 V.
The ignition is on.
The diagnostics tool is connected.
– Press on the metal plate and disconnect the fuel hose connection 1.
Info
Remaining fuel may run out of the fuel hose.
302037-10
400927-01
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 64)
– Disconnect the battery. ( p. 84)
– Drain the fuel from the fuel tank into a suitable container.
Main work
– Remove screws 1.
300562-10
300563-10
300564-10
202046-10
– Remove screws 5.
– Pull out the fuel pump.
202047-10
202048-10
202049-10
202050-10
202051-10
202048-10
202047-10
202046-10
300564-10
300563-10
300562-10
Finishing work
– Disconnect the battery. ( p. 85)
– Mount the seat. ( p. 65)
– Set the clock. ( p. 100)
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 64)
– Disconnect the battery. ( p. 84)
– Drain the fuel from the fuel tank into a suitable container.
Main work
– Remove screws 1.
300562-10
300563-10
300564-10
202046-10
– Remove screws 5.
– Pull out the fuel pump.
202047-10
202048-10
202047-10
202046-10
300564-10
300563-10
300562-10
Finishing work
– Disconnect the battery. ( p. 85)
– Mount the seat. ( p. 65)
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
Warning
Danger of accidents Uncontrollable vehicle handling in the event of a flat tire.
– In the interest of safety, replace damaged or worn tires immediately.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of 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.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be
roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not
achieved until the tires have been run in.
Info
The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tires exhibit cuts, run-in objects or other damage:
– Change the tires.
– Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Info
The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the 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 5 years.
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay.
– Check the thickness of the front and rear brake discs in several places to ensure
that it conforms to measurement A.
Info
Wear reduces the thickness of the brake disc at the contact surface 1 of
the brake disc.
Warning
Danger of accidents Instable handling due to incorrect spoke tension.
– Ensure that the spoke tension is correct.
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.
Info
The frequency of the tone is a function of the spoke length and spoke diam-
eter.
If you hear different tone frequencies from individual spokes of the same
length and thickness, this is an indication of different spoke tensions.
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.
Check the spoke tension regularly, especially on a new motorcycle.
Radial run-out
outside of the rim joint < 1.8 mm (< 0.071 in)
» If the measured value is greater than the specified value:
– Center the rim.
Info
Center the rim by tightening the spoke nipple on the opposite side of
the rim run-out. Change the rim if it is excessively deformed.
400998-01
101060-01
– Remove screw 1.
– Loosen screw 2.
101061-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
101062-10
800080-10
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Main work
– Remove screws 1. Take off the brake disc.
202087-10
202087-10
Finishing work
– Install the front wheel. ( p. 76)
100267-10
– Push the rear wheel forwards as far as possible and take the chain off the rear
sprocket.
Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake discs are not
damaged.
Info
Do not operate the foot brake when the rear wheel is removed.
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 No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.
Main work
– Check the rear hub rubber dampers. ( p. 82)
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Replace the wheel bearing.
– Remove bushing 1. Clean and grease the contact surfaces of the bushings of shaft
seal ring 2.
Long-life grease ( p. 214)
– Clean and grease the thread of the wheel spindle and nut 3.
100269-10 Long-life grease ( p. 214)
– Install the rubber damper and rear sprocket carrier in the rear wheel.
– Position the rear wheel.
The brake linings are correctly positioned.
– Push the rear wheel forward as far as possible and lay the chain on the rear
sprocket.
– Install the wheel spindle, the chain adjusters and the nut.
Guideline
In order that the rear wheel is correctly aligned, the markings on the left and
right chain adjusters must be in the same position relative to the reference
marks A.
Info
100270-10
Mount the left and right chain adjusters 4 in the same position.
– Tighten nut 3.
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.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 10)
202088-10
202088-10
Finishing work
– Install the rear wheel. ( p. 77)
– Remove the motorcycle from the lift stand. ( p. 10)
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
Info
The upper chain section C must be taut.
Chain wear is not always even. Repeat this measurement at different chain
positions.
100249-10
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
Preparatory work
– Check the chain tension. ( p. 79)
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 on the left and right.
Guideline
Chain tension 5 mm (0.2 in)
Turn the left and right adjusting screws 3 so that the markings on the left
and right chain adjusters 4 are in the same position relative to the reference
marks C. The rear wheel is then correctly aligned.
Info
The upper chain section must be taut.
Chain wear is not always even. Repeat this measurement at different chain
positions.
– Tighten nuts 2.
– Make sure that the chain adjusters 4 are installed correctly on adjusting screws 3.
– Tighten nut 1.
Guideline
100250-10
Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)
100299-10
13.7.8 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 10)
Main work
– Shift the transmission to neutral.
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the power set.
Info
The engine sprocket, rear sprocket, and chain should always be
replaced together.
100132-10
– Pull on the upper section of the chain with the specified weight A.
Guideline
Weight of chain wear measurement 15 kg (33 lb.)
0
A – Measure distance B 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.
B
0 Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
1 2 3 16 17 18
400987-10
401118-01
401119-01
Info
Wear is visible on the front of the chain guide.
400985-01
101068-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 10)
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.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
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
The service life of the chain depends largely on its maintenance.
400725-01
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.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 10)
– Remove the rear wheel. ( p. 77)
Main work
– Check bearing 1.
» If the bearing is damaged or worn:
– Replace the bearings.
– Check rubber dampers 2 of the rear hub for damage and wear.
» If the rubber dampers of the rear hub are damaged or worn:
– Change all rubber dampers in the rear hub.
100271-10
– Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert
the wheel spindle in the hub.
– To check play A, hold the rear wheel tight and try to rotate the rear sprocket with
your hand.
Info
Measure the play on the outside of the rear sprocket.
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 64)
Main work
– Disconnect the negative (minus) cable of the battery.
– Pull plug 1 off upward.
– Remove screws 2.
– Pull the retaining bracket 3 of the battery forward and remove it.
– Take off the positive pole cover 4.
– Disconnect the positive (plus) cable of the battery.
– Push the wiring harness to the side and pull the battery out of the battery holder.
100277-10
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle is therefore no longer roadworthy.
Info
The battery terminals must be at the rear.
Main work
– Disconnect the negative (minus) cable 1 of the battery.
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components can safety equipment can be dam-
aged. The vehicle is therefore no longer roadworthy.
300199-11
300199-11
Finishing work
– Mount the seat. ( p. 65)
– Set the clock. ( p. 100)
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– 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.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it still loses power steadily.
The charging level and the method of charging 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.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 64)
– Remove the battery. ( p. 84)
Main work
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing 2.
100151-10
Finishing work
– Install the battery. ( p. 84)
– Mount the seat. ( p. 65)
– Set the clock. ( p. 100)
302035-10
Charging voltage
5,000 rpm 13.5… 15.0 V
» If the displayed value is less than the specified value:
– Check the plug-in connections from the alternator to the voltage regulator.
– Check the plug-in connections from the voltage regulator to the wiring har-
601014-10 ness.
– Check the stator winding of the alternator. ( p. 176)
» If the displayed value is greater than the specified value:
– Change the voltage regulator.
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 64)
Main work
– Remove protection covers 1.
600604-10
Info
A reserve fuse 3 is located in the starter relay.
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 64)
Main work
– Open fuse box cover 1.
600604-11
Info
A defective fuse is indicated by a burned-out fuse wire A.
600606-10
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are
used.
– Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.
Tip
Put a new spare fuse in the fuse box for future use if needed.
100237-10
– Turn the adjusting wheel until the desired digit is next to marking 2.
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 responsive-
ness.
100238-10 Set the Map‑Select switch to Standard.
– Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.
Standard – homologated performance with balanced responsiveness.
Set the Map‑Select switch to poor fuel quality.
– Set the adjusting wheel to position 0.
Poor fuel quality – homologated performance is reduced in accordance with
the fuel quality, use for no more than 1 tank of fuel
– Position the Map‑Select switch in the holder.
– Slide the Map‑Select switch with the holder downward onto the retaining bracket.
Finishing work
– Mount the seat. ( p. 65)
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately.
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally.
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 comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
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. 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. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Press the brake caliper by hand onto the brake disc in order to retract the brake
pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir,
extracting it by suction if it does.
Info
Make sure when pushing back the brake pistons that you do not press the
100254-11 brake caliper against the spokes.
– Remove cotter pin 4, remove pin 5 toward the right by striking it, and remove the
brake linings.
– Clean brake caliper and brake caliper support.
400418-11
– Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake
caliper support are seated correctly.
400418-10
– Insert the brake linings, insert the pin, and mount the cotter pin.
– Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
101057-01
Info
Clean up overflowed or spilt brake fluid immediately with water.
100254-12
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due
to overheating. Adjust the free travel on hand brake lever according to specifications.
– Push the hand brake to the handlebar and check free travel A.
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the free travel of the hand brake lever. ( p. 92)
100251-10
Info
Turn the adjusting screw clockwise to reduce free travel. The pressure point
moves away from the handlebar.
Turn the adjusting screw counterclockwise to increase free travel. The pres-
sure point moves towards the handlebar.
The range of adjustment is limited.
100252-10 Turn the adjusting screw by hand only, and do not apply any force.
Do not make adjustments while riding.
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
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer 1.
» When the brake fluid level drops below the MIN mark:
– Add front brake fluid. ( p. 93)
100253-10
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.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. ( p. 90)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Measurement of A 5 mm (0.2 in)
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 comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with
fresh brake fluid.
Bleed syringe (50329050000) ( p. 216)
Brake fluid DOT 4 / DOT 5.1 ( p. 212)
301891-10
– Pull off protection cap 4 and connect a commercially available suction device
(standard workshop equipment).
– Release bleeder screw 5 and draw out the old brake fluid.
Info
During suction, ensure that the brake fluid reservoir is always filled with a
sufficient amount of fresh brake fluid.
– Tighten the bleeder screw. Remove the suction device and mount the protection
cap.
301892-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
100254-12
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately.
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally.
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 comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
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. 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. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
101059-10
– Remove cotter pin 3, remove pin 4 toward the left by striking it, and remove the
brake linings.
– Clean brake caliper and brake caliper support.
100288-10
– Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake
caliper support are seated correctly.
400419-11
– Insert the brake linings, insert the pin, and mount the cotter pin.
– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
– Adjust the brake fluid level to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 212)
– Mount the screw cap with the membrane.
Info
100289-01 Clean up overflowed or spilt brake fluid immediately with water.
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 the free travel on foot brake lever according to specifications.
– Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel A.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
Info
You will know that contact has been made with the foot brake cylinder pis-
ton when there is increased resistance when you activate the foot brake
lever.
100256-10
» If the free travel does not meet specifications:
– Adjust the basic position of the foot brake lever. ( p. 96)
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 the free travel on foot brake lever according to specifications.
Info
The range of adjustment is limited. The screw must be screwed into the
footrest bracket by at least four turns.
– Position foot brake cylinder 4 so that the foot brake lever has the necessary free
travel. Hold screws 3 in place and tighten the nuts.
Guideline
Screw connection, foot brake cylinder M6 10 Nm (7.4 lbf ft)
– Check the free travel of the foot brake lever. ( p. 96)
– Tighten nut 1.
B01291-10
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
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
101058-10
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.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule.
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Preparatory work
– Check the rear brake linings. ( p. 94)
Main work
– Stand the vehicle upright.
– Remove screw cap 1 with the washer and membrane 2.
– Add brake fluid to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 212)
– Mount the screw cap with the washer and membrane.
Info
101059-10 Clean up overflowed or spilt brake fluid immediately with water.
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 comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
301893-10
– Pull off protection cap 4 and connect a commercially available suction device
(standard workshop equipment).
– Release bleeder screw 5 and draw out the old brake fluid.
Info
During suction, ensure that the brake fluid reservoir is always filled with a
sufficient amount of fresh brake fluid.
– Tighten the bleeder screw. Remove the suction device and mount the protection
cap.
301894-10
– Add brake fluid to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 212)
– 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.
Info
If you change the unit, the value 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 to position ON .
– Press the M button repeatedly until the Odo mode is active.
– Keep the M button pressed until the display mode changes from km/h to mph or
from mph to km/h.
Guideline
Activation duration of M button 10 s
800083-15
Info
The TRIP 1 trip counter runs constantly 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.
800083-19
Info
The TRIP 2 trip counter runs constantly 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.
800083-20
Danger
Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub-
lic roads in the homologated version.
– If the vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle
owner and rider of this.
– If you undertake any modifications, please insist on receiving a signed workshop order from your customer in which you
inform the customer in writing that these modifications are performed at the customer's own risk and that the vehicle will
no longer be approved for use on public roads once modified.
Condition
The motorcycle is stationary.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 102)
Main work
– Unplug connector DO from the combination instrument.
400657-10
800083-26
Finishing work
– Install the headlight mask with the headlight. ( p. 103)
– Check the headlight setting. ( p. 102)
Info
101064-10
If you have a heavy payload, you will need to correct the headlight range.
– Tighten screw 1.
101063-10
– Disconnect the electrical plug-in connection 3 and remove the headlight mask
with the headlight.
800102-10
800102-11
Info
Make sure that the holding lugs engage in the fender.
– Position the brake line and wiring harness. Position the clamp, and mount and
tighten screw 3.
101063-11
Finishing work
– Check the headlight setting. ( p. 102)
Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease
before mounting.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 102)
Main work
– Pull bulb socket 1 out of the reflector.
– Pull parking light bulb 2 out of the bulb socket.
– Insert a new parking light bulb in the bulb socket.
Parking light (W5W / socket W2.1x9.5d) ( p. 182)
– Insert the bulb socket in the reflector.
800100-10
Finishing work
– Install the headlight mask with the headlight. ( p. 103)
– Check the headlight setting. ( p. 102)
Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease
before mounting.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the headlight mask with the headlight. ( p. 102)
Main work
– Pull off connectors 1, 2 and 3.
– Take off protection cap 4 of the headlight bulb.
800098-10
Finishing work
– Install the headlight mask with the headlight. ( p. 103)
– Check the headlight setting. ( p. 102)
Note
Damage to reflector Reduced brightness.
– 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.
Main work
(690 Enduro R EU/AUS/UK)
– Remove the screw on the rear of the turn signal housing.
– Tilt headlamp diffuser 1 forward carefully and take it off.
– Lightly squeeze the orange plug 2 in the area of the holding lugs and take it
off.
– Press the turn signal bulb carefully into the socket, turn it counterclockwise by
about 30°, and take it out of the socket.
100301-10 Info
Do not touch the reflector with your fingers, and keep it free from
grease.
– Press the new turn signal bulb carefully into the socket and turn it clockwise
until it stops.
Turn signal (R10W / socket BA15s) ( p. 182)
– Mount the orange plug.
– Position the diffuser.
– Insert the screw and turn it counterclockwise first until it engages in the thread.
Tighten the screw slightly.
(690 Enduro R USA)
– Remove the screw on the rear of the turn signal housing.
– Tilt headlamp diffuser 1 forward carefully and take it off.
– Press the turn signal 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 turn signal bulb carefully into the socket and turn it clockwise
until it stops.
Turn signal (RY10W / socket BAU15s) ( p. 182)
– Position the diffuser.
– Insert the screw and turn it counterclockwise first until it engages in the thread.
Tighten the screw slightly.
Finishing work
– Check that the turn signal system is functioning properly.
300211-10
– Remove screws 2.
300212-10
– Remove screws 3.
– Take off the engine sprocket cover.
– Remove screw 4.
– Take off the shift lever.
300213-10
300214-10
Info
The rear wheel must be fully removed.
300215-10
Info
Do not bend the clutch line.
Do not activate the clutch lever if the clutch slave cylinder has been
removed.
300216-10
300217-10
– Disconnect connector bk of the gear position sensor, the crankshaft position sensor,
and the alternator.
– Remove the cable binders and release the cables.
300218-10
300188-10
– Loosen the spring-loaded band-type clamp bm from the breather, SLS and oil return
line with the special tool.
Pliers for spring band clamp (60029057100) ( p. 218)
300220-10
300221-10
– Position the floor jack under the engine and fix it using the special tool.
Floor jack attachment (75029055000) ( p. 222)
300222-10
300223-10
300225-10
Info
You should have an assistant for this step.
Make sure that the engine is sufficiently secured against falling over.
Protect the frame and attachments from damage.
300224-10
Main work
– Position the engine in the frame.
– Mount swingarm pivot 1.
– Mount the screw of the swingarm pivot but do not tighten yet.
300225-11
– Install the screw and nut 2 of the lower engine bracket, but do not tighten them
yet.
300223-11
300222-10
300220-11
300219-11
– Reconnect plug-in connections 7 of the gear position sensor, the crankshaft posi-
tion sensor and the alternator.
300218-11
300217-11
– Position the electrical connection 9 on the starter motor. Mount and tighten screw.
Guideline
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft)
– Position the ground wire on the starter motor. Mount and tighten screw bk.
Guideline
Screw, starter motor M6 10 Nm Loctite® 243™
(7.4 lbf ft)
300216-11
300215-11
300214-12
300212-11
– Position the radiator hoses. Install the spring band clamps bt.
– Install the manifold. ( p. 58)
– Install the air filter box. ( p. 62)
– Disconnect the battery. ( p. 85)
300211-11
– Remove the oil filler plug with O-ring ck from the clutch cover and fill up with
engine oil.
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 212)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 212)
– Install and tighten the oil filler plug with O-ring ck.
300802-10
Finishing work
– Fill/bleed the cooling system. ( p. 167)
– Remove the motorcycle from the work stand. ( p. 11)
– Take a short test ride.
– Read out the fault memory using the KTM diagnostics tool.
Info
Have an assistant help you or use a crane.
300144-10
300002-10
300161-10
300001-01
300003-10
300004-10
302124-10
302126-10
– Remove O-ring 2.
– Remove contact pin 3 and the contact springs 4.
300007-10
300009-10
– Remove screws. Remove the oil filter cover 3 with the O-ring.
– Pull oil filter 4 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 216)
300011-10
300010-10
300023-10
– Remove screw 2.
Info
Look through the hole to check that the position hole of the balancer shaft
is visible.
300024-10
300012-10
Info
Do not lose the centering pins.
300013-10
300014-10
300015-10
300154-10
300016-10
300017-10
300019-10
– Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft
gear. Remove the camshaft.
300020-10
300029-10
Info
Push the cylinder upward only far enough to allow removal of the piston pin.
Ensure that the two grooved pins remain in place.
300030-10
Info
If no other work is required on the cylinder and the piston, you can leave the
piston in the cylinder.
Info
Ensure that the two grooved pins remain in place.
300044-10
Info
The crankshaft must not be blocked.
300040-10
– Install the special tool 2 on the rotor. Hold it tight using the special tool and pull
off the rotor by turning the screw in.
Extractor (58429009000) ( p. 216)
– Remove the special tool.
302120-10
Info
The support bushing is plugged through the timing chain guide rails into the
timing chain securing guide.
– Remove the timing chain guide rails upward out of the timing chain shaft.
300045-10
– Hold the timing chain securing guide tight and pull the timing chain tensioning
rail 4 out of the timing chain securing guide.
– Remove the timing chain tensioning rail upward out of the timing chain shaft.
– Remove the timing chain securing guide 3.
300046-10
Info
Mark the direction of travel.
300148-10
300149-10
300151-10
Info
Apply the special tool with the hand only, do not use another tool.
300051-10
– Loosen the screws 2 diagonally and remove them with their spring retainers and
clutch springs.
– Remove the pressure cap 3.
300052-10
300053-10
– Hold the clutch cage using the special tool and remove the nut 6 of the inner
clutch hub.
Gear segment (75029081000) ( p. 222)
Info
Make sure that the crankshaft is not blocked.
300054-10 Info
Left-handed thread!
302125-10
300056-10
300062-10
300064-10
300065-10
300066-10
300067-10
300069-10
300070-10
300071-10
300072-10
300075-10
Info
Use the 750 drill hole.
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.
300077-10
300078-10
300079-10
300080-10
Info
Ensure that the pins remain in place.
300081-10
300082-10
Info
The stop disk of the countershaft usually sticks to the bearing.
300083-10
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
Info
300095-10
The shaft seal ring must be flush on the outside.
– Press in the shaft seal rings of the water pump with the open side facing out so
that it is flush.
Info
The shift shaft bearing 9 must be pressed in from the outside to the inside
until it is flush.
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer bearing race; otherwise, the bear-
300096-10
ings will be damaged when they are pressed in.
– After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
Info
The shaft seal ring 4 of the crankshaft cannot be removed before the
crankshaft bearing.
– Screw off the membrane support plate 5 and remove it together with
membrane 6.
– Remove screw A with the washer.
302590-10
– Remove screw plug 7 and take pressure spring 8 with piston valve 9 out of the
drill hole.
– Remove any sealing mass remnants and clean the engine case section thoroughly.
– Warm the engine case section in an oven.
Guideline
150 °C (302 °F)
– Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
300160-10
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
– Press out the shaft seal ring of the crankshaft from the outside to the inside.
– Press in the shaft seal ring of the crankshaft from the inside to the outside with the
open side facing out.
Info
The shaft seal ring must be flush on the outside.
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 bearing race; otherwise, the bear-
ings will be damaged when they are pressed in.
– After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine case when warm. In this case, the engine case must be
renewed.
– Lubricate piston valve 9 and mount it with pressure spring 8. Mount and tighten
screw plug 7 with the new seal ring.
Guideline
Oil pressure regulator valve plug M12x1.5 20 Nm
(14.8 lbf ft)
– Position the membrane support plate 5 with membrane 6. Mount and tighten the
screws.
Guideline
300093-10 Screw, membrane fixation M3 2.5 Nm Loctite® 243™
(1.84 lbf ft)
Info
The membrane support plate is curved and must point away from the mem-
brane.
An incorrectly installed membrane support plate results in loss of perfor-
mance and increased oil consumption or leaks.
Do not apply thread locker between the membrane and the membrane sup-
port plate since this would impair their function.
Info
Support the clutch cover sufficiently when pressing in.
– Blow compressed air through the oil channel and check that it is clear.
300097-10
300135-10
300133-10
17.4.6 Changing the connecting rod, conrod bearing, and crank pin
Preparatory work
– Remove the crankshaft bearing inner ring. ( p. 127)
– Remove the drive wheel of the balancer shaft. ( p. 127)
Main work
– Position the crankshaft with the special tool 1 in the press.
Under part, pressing-out tool (75029047051) ( p. 221)
– Position the special tool 2 between the crankwebs.
Upper part, pressing-out tool (75029047050) ( p. 221)
– Press the crank pin with the push-out drift of the special tool out of the upper
crankweb.
300137-10 Pressing device for crankshaft, complete (75029047000) ( p. 221)
Info
Hold the lower crankweb.
300138-10
Info
The crank pin must be pressed in so that oil channel A is aligned with oil
channel B.
If the oil channels are not correctly aligned, the conrod bearing will not be
supplied with oil.
– Blow compressed air through the oil channel to check that it is clear.
300140-10
Info
Thoroughly lubricate the bearing.
300141-10
300142-10
Info
The press mandrel must be applied above the crank pin.
– Take the crankshaft out of the special tool, and check the connecting rod for free-
dom of movement.
300139-10
– Measure the axial clearance between the connecting rod and the crankwebs using
the special tool 8.
Feeler gauge (59029041100) ( p. 218)
Finishing work
– Check the crankshaft run-out at the bearing pin. ( p. 129)
– Install the drive wheel of the balancer shaft. ( p. 129)
300132-10
300159-10
Finishing work
– Install the crankshaft bearing inner ring. ( p. 129)
– Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 130)
Info
After changing the crankshaft bearing and the conrod bearing, measure the
axial play of the crankshaft.
Finishing work
– Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 130)
Info
Do not forget the dowels.
Info
If the axial clearance is too small, remove compensation shims.
If the axial clearance is too large, add compensation shims.
Info
If the axial clearance is too small, remove compensation shims.
If the axial clearance is too large, add compensation shims.
302591-10
300103-10
– Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
Feeler gauge (59029041100) ( p. 218)
0
A » If clearance A is larger than the specified value:
– Change the piston and piston rings.
400484-10 – Check/measure the cylinder. ( p. 131)
– Check the piston bearing surface for damage.
» If the piston bearing surface is damaged:
– Change the piston and, if necessary, the cylinder.
– Check that the piston rings can move easily in the piston ring grooves.
» If the piston ring is stiff:
– Clean the piston ring groove.
Tip
300099-10 Use an old piston ring to clean the piston ring groove.
Info
Mount the piston ring with the marking facing upward.
Info
Piston size 1 is marked on the piston head.
Info
The oil pump wear check shown here is on the suction pump but it applies to all oil pumps.
– Use a feeler gauge 1 to measure the play between the external rotor and the
engine case as well as between the external rotor and the internal rotor.
Oil pump
Clearance between external rotor ≤ 0.20 mm (≤ 0.0079 in)
and engine case
Clearance between external rotor ≤ 0.20 mm (≤ 0.0079 in)
and internal rotor
Axial clearance 0.04… 0.08 mm (0.0016…
300106-10 0.0031 in)
» If the measured value does not meet specifications:
– Change the oil pump and, if necessary, the engine case.
300107-10
300108-10
300109-10
– When assembling, first connect the autodecompression spring and then insert the
screw through the autodecompression weight.
The arm of the autodecompression spring 5 is long enough to pass right
through the autodecompression weight.
– Position the autodecompression weight. Mount and tighten screw 3. Reconnect
the autodecompression spring.
Guideline
Screw, autodecompression M6 3… 4 Nm Loctite® 243™
(2.2…
300110-10
3 lbf ft)
– Mount the autodecompression shaft in the camshaft. Install a new lock ring.
– Check the functioning.
» If the autodecompression spring does not completely retract the autodecom-
pression shaft:
– Replace the autodecompression spring.
Info
This requires considerable force since the oil has to be pressed out.
200171-10
– Place two compensating disks or similar aids next to the piston of the timing chain
tensioner. This should ensure that when pushed down, the piston does not fully
withdraw.
Guideline
Thickness of the compensating disks 2… 2.5 mm (0.08… 0.098 in)
– Release the timing chain tensioner.
The latching system locks and the piston stops moving.
End position of piston after latching 3 mm (0.12 in)
200172-10
Info
This position is necessary for installation.
If the timing chain tensioner is now pressed in once more (while it is
installed) and then pulled out no more than halfway (preventing it from
coming out fully), the latching system locks and the timing chain tensioner
can no longer be compacted; this function is necessary to ensure sufficient
tension of the timing chain, even at low oil pressure.
300113-10
– Screw a suitable screw 3 into the rocker arm shafts 2. Pull out the rocker arm
shafts.
– Take off the rocker arm 4.
300114-10
300226-10
300228-10
– Press in the small camshaft bearing as far as possible using the special tool 3.
Push-in drift (75029044020) ( p. 221)
300229-10
– Press in the large camshaft bearing as far as possible using the special tool 4.
Push-in drift (75029044010) ( p. 220)
300230-10
Finishing work
– Install the rocker arm. ( p. 139)
300115-10
Info
Place the valves into a box according to the installation position and label
the box.
300117-10
200193-10
0
A Valve - sealing seat width
Exhaust 2.00 mm (0.0787 in)
» If the sealing area is not in the center of the valve seat or deviates from the
specified value:
400373-10
– Machine the valve seat.
300118-10 » If the measured value does not equal the specified value:
– Change the valve spring.
– Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) ( p. 218)
0
A Valve - sealing seat width
Exhaust 2.00 mm (0.0787 in)
» If the measured value does not equal the specified value:
– Machine the valve seat.
400373-10
– Blow compressed air through all oil channels and check that they are clear.
5
0
4
0
2
0 1
0
0
3
0
300118-01
300116-11
Info
When mounting the valve keys, check that they are seated correctly; prefer-
ably, fix the valve keys to the valve with a little grease.
– Place shims 5 into the valve spring retainers according to the installation position.
300115-11
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.
300114-11
300113-11
Info
Use soft jaws.
300120-10
– Take the clutch out of the vise and lay it on a clean workbench with the outer
clutch hub 5 facing down.
– Take the inner clutch hub 3 and release springs 4 out of the outer clutch hub 5.
300121-10
– Take off the clutch facing discs 6 from the inner clutch hub.
– Remove pretension ring 7 and support ring 8.
– Clean all parts well.
– Check the clutch. ( p. 139)
300122-10
4
0 bk
0
5
0
2
0 b0l
bl 6 0
0 9
1
0
3
0 bbo
0o
b0n
bn b0m
bm
0
7 8
0
300123-01
Main work
– Check pressure piece 1 for damage and wear.
» If there is damage or wear:
– Replace the pressure piece.
– Check axial bearing 2 for damage and wear.
» If there is damage or wear:
– Change the axial bearing.
– Place push rod 3 on a level surface and check it for run-out.
» If there is run-out:
– Change the push rod.
– Check the length of clutch springs 4.
Clutch spring - length 31.5… 33.5 mm (1.24… 1.319 in)
» If the clutch spring length is less than the specified value:
– Change all clutch springs.
– Check the contact surface of pressure cap 5 for damage and wear.
» If there is damage or wear:
– Change the pressure cap.
– Check the contact surfaces of the clutch facing discs in the outer clutch hub 6 for wear.
Clutch basket - contact surface of clutch facing discs ≤ 0.5 mm (≤ 0.02 in)
» If the contact surface is very worn:
– Change the clutch facing discs and the outer clutch hub.
– Check needle bearing 7 and supporting plate 8 for damage and wear.
» If there is damage or wear:
– Replace the needle bearing and supporting plate.
– Check the intermediate clutch discs 9 for damage and wear.
» If the intermediate clutch discs are not even or are pitted:
– Change all intermediate clutch discs.
Finishing work
– Preassemble the antihopping clutch. ( p. 141)
Info
The pretension ring must be installed so that it is flush with the inner
edge A on the support ring.
300123-10
– Position the trimmed clutch facing disc with the recess for the pretension ring on
the outer clutch hub.
– Beginning with the coated intermediate clutch disc, position all further clutch fac-
ing discs and intermediate clutch discs alternately.
– Position the release springs 3.
300124-10
– Push on the outer clutch hub 4 and pay attention to the markings.
The arrow 6 of the outer clutch hub must point to the notch 5 of the inner
clutch hub.
– Push the two clutch hubs firmly together and have an assistant screw in the special
tool.
Assembly screws (75029033000) ( p. 220)
Info
300125-10 Apply the special tool with the hand only, do not use another tool.
Apply the special tool only firmly enough so that the clutch facing discs
can still be turned against each other since they still have to be aligned for
mounting in the clutch basket.
0
A » If there is damage or wear:
– Change the shift fork and gear wheel pair.
0
1 4 0
0 1 – Check shift grooves B of shift drum 2 for wear.
D
0 4
0 » If the shift groove is worn:
6
0 1
0 – Change the shift roller.
–
C0E Check the seat of the shift drum in the bearings 3.
0 5
0 » If the shift roller is not seated correctly:
– Replace the shift drum and/or the bearing.
– Check bearing 3 for stiffness and wear.
» If the bearings do not move freely or are worn:
– Replace the bearings.
0
2 – Check the needle bushing 4 for stiffness and wear.
0
3 » If the needle bushing does not move freely or is worn:
B
0 – Replace the needle bushing.
0
3 – Check the shift rail 5 on a flat surface for run-out.
» If there is run-out:
300120-01
– Change the shift rail.
– Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
– Change the shift rail.
– Check sliding plate 6 in contact areas C for wear.
» If the sliding plate is worn:
– Change the sliding plate.
– Check return surface D on the sliding plate for wear.
» If deep notches are present:
– Change the sliding plate.
– Check guide pin E for looseness and wear.
» If the guide pin is loose and/or worn:
– Change the sliding plate.
– Preassemble the shift shaft. ( p. 142)
– Check the clearance F between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift 0.40… 0.80 mm (0.0157…
quadrant 0.0315 in)
F
0 » If the measured value does not equal the specified value:
– Change the sliding plate.
0
300122-01
13
0 – Mount sliding plate 1 with the guide pin facing down and attach the guide pin to
2 –
the shift quadrant.
Mount preload spring 2.
– Push on spring guide 3, push return spring 4 over the spring guide with the offset
46 end facing upward and lift the offset end over abutment bolt 5.
300154-01
– Mount stop disk 6.
bl bk
9
8
7 6
5 1
3 4
2 301980-01
– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws.
– Remove stop disk 1 and second-gear fixed gear 2.
– Remove the sixth-gear idler gear 3.
– Remove the split needle bearing 4 and stop disk 5.
– Remove lock ring 6.
– Remove the third/fourth-gear sliding gear 7.
– Remove lock ring 8.
– Remove stop disk 9 and fifth-gear idler gear bk.
– Remove bearing bush bl.
2
4
1 6
3 8
5 bk bl
7
bm bq
bn 9
bo bp
br bs
300128-01
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
0
4
9
1
0
0
5
2
7
6
0 0
4
1
0
0
7
6 6
5
0
0
8
7 7
6
0
8
7
7
6
0 0
8
7
7
6
0
40
01 0
7
6
8
7
0 7
6
0
5
0 7
6
0
8
7
0
40
14
0
1
0 3
5
0
4
0
9
1
0 305511-01
Info
Use new lock rings in every repair job.
Preparatory work
– Oil all parts carefully before assembling.
– Check the transmission. ( p. 144)
Main work
1 2
3
4
5 6
7 bl
9 8
bk 301980-02
– Fix the main shaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Lubricate and mount bearing bush 1.
Long-life grease ( p. 214)
– Push on the fifth-gear idler gear 2 with the shift dogs facing upward.
– Mount stop disk 3 and lock ring 4.
– Push on the third/fourth-gear sliding gear 5 with the small gear wheel facing downward and mount lock ring 6.
– Push on stop disk 7 and split needle bearing 8.
– Push on the sixth-gear idler gear 9 with the shift dogs facing downward.
– Push on the second-gear fixed gear bk with the collar facing downward and mount stop disk bl.
– Finally, check all gear wheels for smooth operation.
Info
Use new lock rings in every repair job.
Preparatory work
– Oil all parts carefully before assembling.
– Check the transmission. ( p. 144)
Main work
bq
bn
br 8
bp bk
bo 8 9
bm
7 3
6 bl
5 4
2 1
300128-02
– Fix the countershaft in the vise with the geared end facing downward.
Guideline
Use soft jaws
– Lubricate and mount bearing bush 1.
Long-life grease ( p. 214)
– Mount second-gear idler gear 2 on the countershaft with the protruding collar facing downward.
– Mount stop disk 3 and lock ring 4.
– Mount the sixth-gear sliding gear 5 with the shift groove facing upward.
– Mount lock ring 6 and stop disk 7.
– Mount needle bearing 8 and the fourth-gear idler gear 9 with the collar facing upward.
– Mount needle bearing bk and the third-gear idler gear bl with the collar facing downward.
– Mount stop disk bm and lock ring bn.
– Mount the fifth-gear sliding gear bo with the shift groove facing downward and stop disk bp.
– Mount needle bearing bq, first-gear idler gear br with the recess facing downward, and stop disk bs.
– Finally, check all gear wheels for smooth operation.
5
6
1
2
4 3
300129-01
– Check the teeth and seating of the starter idler gear 1 for damage and wear.
» If there is damage or wear:
– Replace the starter idler gear and/or needle bushing.
– Check the teeth and seating of the torque limiter 2 for damage and wear.
» If there is damage or wear:
– Replace the torque limiter and/or needle bushing.
– Check freewheel gear 3 and bearing when removed for damage and wear.
» If there is damage or wear:
– Replace the freewheel gear and/or the bearing.
– Check freewheel 4 when removed for damage and wear.
» If there is damage or wear:
– Replace the freewheel.
– Check the toothing of the starter motor 5 for damage and wear.
» If there is damage or wear:
– Replace the starter motor.
– Clamp the minus (negative) cable of a 12 Volt power supply to the starter motor housing. Briefly connect the plus (positive) cable
of the power supply to the starter motor connection.
» If the starter motor does not turn when you close the power circuit:
– Replace the starter motor.
– Replace the O-ring 6 of the starter motor.
300127-10
– Compress the expansion ring 2 and remove it, using suitable pliers.
– Take the freewheel 3 out of the primary gear.
300128-10
Info
Note the direction of rotation.
300129-10
300128-11
– Make sure that all lugs of the expansion ring locate in the slits A of the freewheel.
Info
If necessary, use a screwdriver to ease them in.
300130-10
– Insert the lock ring 3 into the groove with suitable pliers and check that it is
seated correctly.
300127-11
300087-10
300088-10
– Mount the upper shift fork 3, the middle shift fork 4, and the lower shift fork 5.
Info
For the assembly of the middle shift fork 4, the sliding gear of the
third/fourth gear must be lifted.
300089-10
300090-10
300079-11
300082-11
300085-10
– Push the crankshaft into the bearing seat and take off the special tool.
– Grease the shaft seal rings of the balancer shaft.
– Push the balancer shaft 3 into the bearing seat and take off the special tool.
Align marks A and B.
– Mount stop disk 4.
300165-10
300077-11
– Put on the left engine case half. If necessary, tap lightly with a rubber mallet and
turn the transmission shafts.
Info
Do not tighten the engine case sections using the screws.
300073-10
– Position both oil pump covers 3. Mount and tighten the screws.
Guideline
Screw, oil pump cover M5 6 Nm Loctite® 243™
(4.4 lbf ft)
– Install washers 4 and pins 5.
300071-11
300070-11
300069-11
Info
The flat surfaces A of the shift drum locating are not symmetric.
300068-10
300067-11
300066-11
300065-11
– Push on the starter idler gear 4 with washer. Mount lock ring.
– Push on the needle bearing and torque limiter 5 with washer. Mount lock ring.
300064-11
Info
Turn freewheel gear backwards and forwards to ease meshing.
300063-10
300057-10
Info
Turn the clutch basket and oil pump gear wheels backwards and forwards
slightly to help them mesh more easily.
– Mount the half washers with the sharp edge facing outward.
Info
Grease the half washers to ease assembly.
300058-10
– Position stepped washer with the recesses toward the half washers.
– Insert the clutch package 4 in the clutch cage.
Info
If necessary, turn the main shaft a little to ease access.
Make sure that the upper clutch facing disc is offset by one notch.
302123-10
Info
302121-10
Make sure that the crankshaft is not blocked.
302122-10
300061-10
300052-11
300151-10
300150-10
– Thread the timing chain 2 in and lay it over the timing chain sprocket.
Info
If the timing chain is not new, pay attention to the direction of travel.
300148-11
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 2 from above. Insert the support bush-
ing into the timing chain securing guide.
300046-11
– Thread in the timing chain guide rail 3 from above. Insert the support bushing into
the timing chain securing guide.
– Mount and tighten screws 4.
Guideline
Screw, timing chain guide M6 10 Nm Loctite® 243™
rail (7.4 lbf ft)
Screw, timing chain ten- M6 10 Nm Loctite® 243™
sioning rail (7.4 lbf ft)
300045-11
Info
Ensure that there is no thread locking material at the collar of the screw;
otherwise, the timing chain tension rail could lock and break.
Info
Make sure that the crankshaft is not blocked.
300043-10
300025-10
300032-10
300033-10
300035-10
Info
Make sure the grooved pins are seated correctly.
300034-10
– 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
400366-10
– Insert the special tool and firmly press it toward the piston.
– Turn the special tool counterclockwise, thereby pressing the piston pin retainer into
the groove.
Insertion for piston ring lock (75029035000) ( p. 220)
– Make sure that the piston pin retainer is seated correctly on both sides.
300038-10
300039-10
Info
Make sure the grooved pins are seated correctly.
– Mount the cylinder head. Mount and tighten cylinder head screw 1 with the wash-
ers.
Guideline
Cylinder head screw M10 Tightening Lubricated with
300029-11 sequence: engine oil
Tighten diag-
onally, begin-
ning with the
rear screw on
the timing
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)
Info
Always use new cylinder head screws.
Info
Make sure that the crankshaft is at top dead center.
300163-10
300022-10
300017-11
– Remove screw 3 and use the special tool to push the timing chain tensioner
toward the timing chain.
Release device for timing chain tensioner (77329051000) ( p. 224)
The timing chain tensioner unlocks.
– Mount and tighten screw 3.
Guideline
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft)
sioner
300018-10
300044-10
– Check the valve clearance on all valves between the valve and the rocker arm using
the special tool 2.
Guideline
Valve play, cold 0.07… 0.13 mm (0.0028…
0.0051 in)
306140-10
Info
Make sure that the crankshaft is at top dead center.
300156-10
– Screw suitable screws 2 into the rocker arm shafts 3. Pull out the rocker arm
shafts.
– Take off the rocker arm.
300157-10
– Remove shims 4 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.
The small drill hole and the flat surface must point upwards.
300158-10
300156-11
300016-11
300154-10
300015-11
300014-11
300013-12
300012-12
300010-11
300009-11
300011-11
300007-11
302126-11
302140-10
302124-10
300152-10
– Mount the oil drain plug 1 with the magnet and a new seal ring and tighten it.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
– Mount and tighten screw plug 2 with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
300008-10
300161-11
300005-10
300024-11
300001-01
300003-10
Info
Have an assistant help you or use a crane.
300144-11
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.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Check the fluid level.
Fluid level under top level of container 4 mm (0.16 in)
» If the level of the coolant does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 213)
100281-10
– Position the cover with the membrane. Mount and tighten the screws.
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.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Bleed syringe (50329050000) ( p. 216)
Hydraulic fluid (15) ( p. 213)
– On the clutch slave cylinder, remove bleeder screw 5 and mount bleeding
syringe 4.
– Inject the liquid into the system until it escapes from hole 6 of the master cylinder
without bubbles.
– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten the bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below top edge of container 4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
202086-10
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.
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Preparatory work
– Remove the engine guard. ( p. 36)
Main work
– Stand the motorcycle upright.
– Place a suitable container under the engine.
– Remove screw 1. Remove the radiator cap.
– Completely drain the coolant.
– Mount screw 1 with a new seal ring and tighten it.
Guideline
Plug, drain hole of water pump M10x1 15 Nm
600616-10 (11.1 lbf ft)
Finishing work
– Install the engine guard. ( p. 36)
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
101066-11
101067-10
– Remove the cap from compensating tank 2 and add coolant to the level shown in
the figure.
– Mount the cap of the compensating tank.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
B01293-11 effective exhaust extraction 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.
– Check the coolant level. ( p. 169)
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.
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
Engine is cold.
– Stand the motorcycle on its side stand on a horizontal surface.
– Remove the cap of compensating tank 1.
– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the antifreeze of the coolant.
– Check the coolant level in the compensating tank.
B01293-10 The coolant level must be within the range shown in the figure.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 212)
Alternative 2
Coolant (mixed ready to use) ( p. 212)
– Mount the cap of the compensating tank.
– Screw off the radiator cap 2.
– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the antifreeze of the coolant.
– Check the coolant level in the radiator.
The radiator must be completely filled.
101066-10
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.
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 con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
Engine is cold.
– Stand the motorcycle on its side stand on a horizontal surface.
– Check the coolant level in the compensating tank 1.
The coolant level must be within the range shown in the figure.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 212)
B01293-10 Alternative 2
Coolant (mixed ready to use) ( p. 212)
– Screw off the radiator cap 2 and check the coolant level in the radiator.
The radiator must be completely filled.
» If the coolant level does not meet specifications:
– Correct the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 212)
Alternative 2
101066-10
Coolant (mixed ready to use) ( p. 212)
– Mount the radiator cap.
400500-60
Info
The engine oil level must be checked when the engine is warm.
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– 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:
100210-10
– Add the engine oil. ( p. 175)
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.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Main work
– Remove screw 1.
302039-10
– Position the banjo bolt with the connection and seal rings. Mount and tighten the
banjo bolt.
Guideline
Banjo bolt M10x1 8 Nm (5.9 lbf ft)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
– Change the oil filter. Check oil pumps for wear. Check all oil channels for
free flow.
– 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. In case of burns,
rinse immediately with lukewarm water.
20.4 Changing the engine oil and filter, cleaning the oil screens
– Drain the engine oil. ( p. 172)
– Remove the oil filter. ( p. 173)
– Clean the oil screens. ( p. 174)
– Install the oil filter. ( p. 173)
– Fill up with engine oil. ( p. 175)
601022-10
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.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the engine oil only when the engine is warm.
Preparatory work
– Remove the engine guard. ( p. 36)
Main work
– Place a suitable container under the engine.
– Remove the oil drain plug 1 with the magnet and seal ring.
– Completely drain the engine oil.
100200-10
100201-01
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.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Preparatory work
– Place a suitable container under the engine.
Main work
– Remove screws 1. Remove the oil filter cover 2 with the O-ring.
– Pull oil filter 3 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 216)
100202-10
– Remove screws 4. Take off the oil filter cover 5 with the O-ring.
– Pull oil filter 6 out of the oil filter housing.
Circlip pliers reverse (51012011000) ( p. 216)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.
100203-10
100204-10
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.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Preparatory work
– Place a suitable container under the engine.
Main work
– Remove plug 1 with oil screen 2 and the O-rings.
100205-10
100206-10
100207-10
100208-10
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
Main work
– Remove filler plug with O-ring 1 from the clutch cover and add engine oil.
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 212)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 212)
– Refit plug with O-ring 1 and tighten it.
100209-10
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
Main work
– Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with
engine oil.
Engine oil (SAE 10W/60) (00062010035) ( p. 212)
Engine oil (SAE 10W/50) ( p. 212)
Info
For optimal performance of the engine oil, do not mix different types of
100209-10
engine oil.
If appropriate, change the engine oil.
– Install and tighten the oil filler plug 1 with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Alternator
Resistance of stator winding at: ≤1Ω
20 °C (68 °F)
» If the displayed value is not equal to the setpoint value:
600894-10
– Replace the stator.
Stator winding, measurement II - check the resistance
– Measure the resistance between the specified points.
Stator, connector EN pin 1 – Stator, connector EN pin 3
Alternator
Resistance of stator winding at: ≤1Ω
20 °C (68 °F)
» If the displayed value is not equal to the setpoint value:
– Replace the stator.
600894-10 601014-10
Resistance ∞Ω
» If the displayed value is not equal to the setpoint value:
– Replace the stator.
600893-10
Ignition coil
Resistance of secondary winding 10.4… 15.6 kΩ
at: 20 °C (68 °F)
» If the displayed value is not equal to the setpoint value:
600739-13
– Replace the ignition coil.
22.1 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)
Valve play, cold 0.07… 0.13 mm (0.0028… 0.0051 in)
Crankshaft bearing 2 roller bearings
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication Semi-dry sump lubrication with two rotor pumps
Primary transmission 36:79
Clutch APTC™ antihopping clutch in oil bath/hydraulically operated
Gearbox 6-gears, claw-shifted
Transmission ratio
1st gear 14:35
2nd gear 16:28
3rd gear 21:28
4th gear 21:23
5th gear 23:22
6th gear 23:20
Mixture preparation Electronic fuel injection
Ignition Contactless controlled fully electronic ignition with digital igni-
tion 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
Idle speed
Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,550… 1,650 rpm
Starting aid Electric starter, automatic decompressor
Info
The oil consumption depends on the riding style and on
the operating conditions.
Screw plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite® 243™
Screw plug, oil channel, 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) –
Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) –
head
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) –
Screw plug, oil channel M14x1.5 15 Nm (11.1 lbf ft) Loctite® 243™
Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite® 243™
Rotor nut M18x1.5 100 Nm (73.8 lbf ft) –
Nut, engine sprocket M20x1.5 80 Nm (59 lbf ft) Loctite® 243™
Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite® 243™
Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M20x1.5 25 Nm (18.4 lbf ft) –
Plug, oil thermostat M24x1.5 15 Nm (11.1 lbf ft) –
Screw in alternator cover M24x1.5 8 Nm (5.9 lbf ft) –
22.4 Capacities
22.4.1 Engine oil
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 212)
Alternative engine oil Engine oil (SAE 10W/50)
( p. 212)
22.4.2 Coolant
Coolant 1.20 l (1.27 qt.) Coolant ( p. 212)
Coolant (mixed ready to use) ( p. 212)
22.4.3 Fuel
Total fuel tank capacity, 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 213)
approx.
22.5 Chassis
Frame Lattice frame made of chrome molybdenum steel tubing,
powder-coated
Fork WP Suspension 4860 MXMA
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Suspension travel
Front 275 mm (10.83 in)
Rear 275 mm (10.83 in)
Brake system
Front Disc brake with dual-piston brake caliper, floating
Rear Disc brake with single-piston brake caliper, floating
Brake discs - diameter
Front 300 mm (11.81 in)
Rear 240 mm (9.45 in)
Brake discs - wear limit
Front 4.5 mm (0.177 in)
22.7 Tires
Validity Front tires Rear tires Condition
(690 Enduro R EU/AUS/UK) 90/90 - 21 M/C 54S M+S TT 140/80 - 18 M/C 70R M+S TT To max.: 160 km/h
Continental TKC 80 Continental TKC 80 (99.4 mph)
(690 Enduro R USA) 90/90 - 21 M/C 54R TT 140/80 - 18 M/C 70R TT
Pirelli MT 21 RALLYCROSS Pirelli MT 21 RALLYCROSS
Additional information is available in the Service section under:
http://www.ktm.com
22.8 Fork
Fork part number 14.18.7K.41
Fork WP Suspension 4860 MXMA
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Spring length with preload spacer(s) 495 mm (19.49 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+0 +0
−20 mm (3.94−0.79 in)
Fork oil per fork leg 635 ml (21.47 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 213)
Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 213)
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
– When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors,
cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component.
Excessive pressure can cause malfunctions or destroy these parts.
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
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
401061-01 Never apply motorcycle cleaner to the dry vehicle; always rinse with water
first.
If the vehicle was operated in road salt, clean it with cold water. Warm
water enhances the corrosive effects of salt.
– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Remove the plug from the exhaust system.
Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake
system.
– Clean or dry a dirty or wet brake system by riding and braking gently.
– After cleaning, ride a short distance until the engine reaches operating tempera-
ture.
Info
The heat produced causes water at inaccessible locations in the engine and
brake system to evaporate.
– Push back the protection covers of the handlebar controls to allow any water that
has penetrated to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Clean the chain. ( p. 82)
– Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 214)
– Treat all painted parts with a mild paint polish.
High-luster polish for paint ( p. 214)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care agent.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
surfaces ( p. 215)
– Lubricate the ignition/steering lock.
Universal oil spray ( p. 215)
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 after riding. Warm water would enhance the corrosive effects of
salt.
Info
After EVERY trip on salted roads, thoroughly wash the brake calipers and
brake linings with cold water and dry carefully. This should be done after
the parts are cooled down and while they are installed.
After use on salted roads, clean the motorcycle thoroughly with cold water
and dry it properly.
401060-01
– Treat the engine, the swingarm, and all other bare or galvanized parts (except brake
discs) with a wax-based anti-corrosion substance.
Info
To prevent serious reduction of the braking efficiency, make sure no anti-
corrosion substance gets on to the brake discs.
24.1 Storage
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.
– When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive ( p. 214)
– Ride the motorcycle until the low fuel warning lamp lights up and the display
changes to TRIP F so that you can fill up with fresh fuel when you take the
motorcycle back into service.
– Clean the motorcycle. ( p. 186)
– Change the engine oil and filter, clean the oil screens. ( p. 172)
401058-01
– Check the antifreeze and coolant level. ( p. 168)
– Check the tire air pressure. ( p. 73)
– Remove the battery. ( p. 84)
– Recharge the battery. ( p. 85)
Guideline
Storage temperature of battery without 0… 35 °C (32… 95 °F)
direct sunshine
– Store the vehicle in a dry location that is not subject to large fluctuations in tem-
perature.
Info
KTM recommends jacking up the motorcycle.
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.
401059-01
○ One-time interval
● Periodic interval
1 2 3 4 5 6 7 8
401227-01
-A11
/2.A7
A A
43
DS/44
43
-X18
gn
B B
wh-rd a /2.B1
bl-rd b /2.C1
wh-rd
wh-rd
wh-rd
wh-rd
wh-rd
bl-rd
bl-rd
bl
bl
bl
bl
C -X12 C
-X13 AU/2 -X19 -X9
2
1
AF/4 EB/4 FJ/2
4
2
2
1
1
BI/2
1
1
1
2
2
2
4
-M10 -K10 -G10 -T20 -G20 -K11 -F9
3
30A
1 1
2 2
10A
M
U 3 3 G
CR/1 CR/1
1
EM/3
EN/3
-X292 -X291
3
3
4
1
AF/4 EB/4 FJ/2
1
2
3
3
4
rd-bu
ye-rd
ye-rd
gn
gn
gn
br
br
bl
-X302 -X301
WIRING DIAGRAM
br c /2.F1
F F
690 Enduro R 09/10/11
26.1 110
/
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 193
Components:
A11 EFI control unit
F9 Fuse
G10 Battery
G20 Alternator
K10 Starter relay with main fuse
K11 Start auxiliary relay
M10 Starter motor
T20 Voltage regulator
X291 Connector for accessory ground (terminal 31) ACC 1 (not assigned)
X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)
1 2 3 4 5 6 7 8
401228-01
-A12 -P10 -A11
/7.A6 /3.A3 /1.A5
A /7.A3 A
8
1
CZ/3 DO/8
1
2
8
-X21 CY/3 DN/8 -X18 -X18
1
2
-X62 -X63
wh-rd
wh-bl
ye-rd
ye-rd
br
B B
gn d /3.B1
/1.B8 a wh-rd
/1.C8 b bl-rd e /7.C1
wh-rd
wh-rd
wh-rd
wh-bl
ye-rd
bl-rd
rd
rd
rd
C -X37 -X41 C
BR/4 BY/4 -X1 -X14 -X15
4
4
1
4
2
2
1
BK/4 CV/4
1
1
2
4
2
3
4
-S23 -S11 -F1 -K12 -K30
10A
AP/6
1
6
-X295
BK/4 CV/4
3
4
2
3
3
2
1
1
FJ/2 EB/4 EB/4
1
2
3
4
D BR/4 BY/4 -X1 -X14 -X15 D
2
3
-X37 -X41
wh-rd
wh-rd
ye-rd
ye-rd
ye-rd
ye-rd
ye-rd
gn
br
br
br
br
WIRING DIAGRAM
/1.F8 c br br c /3.F1
F F
690 Enduro R 09/10/11
26.2 2/10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 195
Components:
A11 EFI control unit
A12 EPT control unit
F1 Fuse
K12 Light relay
K30 Power relay
P10 Combination instrument
S11 Ignition/steering lock
S23 Emergency OFF switch, electric starter button
X295 Diagnostics connector
1 2 3 4 5 6 7 8
401229-01
-P10
/2.A3
A /5.A1 A
DO/8 DB/4
3
4
4
2
1
DN/8 DA/4
1
2
3
4
Down 4
-X63 -S36
Mode
Up
bu
B B
/2.B8 d gn gn d /6.B1
wh
gn
gn
bu
bu
gn
gn
gr
gr
br
br
br
C -X34 C
-X7 -X24 AC/6 -X436 -X437 -X6
3
6
4
2
1
1
BC/12 -X29 -X28
1
1
3
6
4
2
2
-F7 -P15 -S29 BP/4 -E13 -P35 DG/4 -F6
3
4
2
1
/5.C1 LO HI
15A
10A
DG/4 BP/4
1
2
3
4
-X28 -X29
BC/12
2
5
2
1
1
1
FJ/2 FF/1 FF/1 FF/1 DI/2 FJ/2
1
1
D -X7 -X25 AC/6 -X434 -X435 -X437 -X6 D
5
-X34
ye-bu
ye-bu
wh
bu
gn
gn
bu
ye
ye
ye
br
br
WIRING DIAGRAM
ye-bu f /4.F1
ye g /4.F1
/2.F8 c br br c /4.F1
F F
690 Enduro R 09/10/11
26.3 3/10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 197
Components:
E13 Low beam, high beam
F6 Fuse
F7 Fuse
P10 Combination instrument
P15 Horn
P35 Parking light
S29 High beam/low beam switch, horn button, turn signal switch
S36 Tripmaster switch (optional)
1 2 3 4 5 6 7 8
401230-01
A A
B B
wh-gn
wh-gn
wh-gn
wh
wh
ye
2
1
DI/2
2
1
2
2
2
1
DI/2
1
D AJ/3 BV/2 -X58 AH/2 AH/2 D
1
2
3
ye-bu
ye-bu
br
br
br
WIRING DIAGRAM
Components:
B76 Front brake light switch
B77 Brake light switch, rear
E60 License plate lamp
P36 Brake/tail light
1 2 3 4 5 6 7 8
401231-01
-P10
/3.A3
A /7.A1 A
DO/8
3
2
DN/8
2
3
-X63
pu
bl
B B
bl-or
pu
pu
pu
br
br
br
bl
bl
bl
C -X30 -X31 -X47 -X46 C
BT/3 -X20 CX/2 CX/2 CX/2 CX/2
3
2
2
1
1
AH/2
2
1
2
2
3
2
-S29 -K20 -P42 -P41 BY/4 -P45 -P46 -X59
2
/3.C3 G CV/4
3
4
LR
CV/4
2
-X59 BY/4
3
4
BG/3 CW/2 CW/2 CW/2 CW/2 -X60
2
1
1
1
AH/2
1
D BT/3 -X20 CX/2 CX/2 CX/2 CX/2 D
1
1
2
2
-X17 -X30 -X31 -X47 -X46
ye-bu
bl-or
pu
pu
br
br
br
bl
bl
WIRING DIAGRAM
/4.F8 f ye-bu
/4.F8 c br br c /6.F1
F F
690 Enduro R 09/10/11
26.5 5/10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 201
Components:
K20 Turn signal relay
P10 Combination instrument
P41 Turn signal, front left
P42 Turn signal, front right
P45 Turn signal, rear left
P46 Turn signal, rear right
S29 High beam/low beam switch, horn button, turn signal switch
1 2 3 4 5 6 7 8
401232-01
A A
B B
/3.B8 d gn
gn
gn
bl
bl
C -X10 C
-X8 -X5 AU/2 -X33
1
FJ/2 FJ/2 AV/2
2
1
BI/2
1
2
2
-F8 -F5 -M14 -B33
10A
10A
CR/1 CR/1 M
1
t°
-X294 -X293
BI/2
2
2
1
1
FJ/2 FJ/2 AV/2
1
2
D -X8 -X5 AU/2 -X33 D
2
-X10
wh-bl
wh-bl
bl-rd
bl-rd
br
br
WIRING DIAGRAM
/5.F8 c br br c /7.F1
F F
690 Enduro R 09/10/11
26.6 6/10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 203
Components:
B33 Temperature switch for radiator fan
F5 Fuse
F8 Fuse
M14 Radiator fan
X293 Connector for accessory ground (terminal 31) ACC 2 (not assigned)
X294 Connector for accessory plus (terminal 15) ACC 2 (not assigned)
26.7 Page 07 of 10
A
F
B
/2.C8 e
/6.F8 c
/8.A7
/5.A1
-P10
ye-rd
br
1
1
br-pu br-pu 1 1
-X62
CY/3
CZ/3
-X300
br-pu
br-pu
2
2
br
690 Enduro R 09/10/11
-F2
/2.A7
/8.A1
-A11
1 10A 2
or 1 2 ye-rd
FJ/2
FJ/2
-X2
-X2
br-pu 3 3
6 6
3
3
or
DS/44
-M13
-X18
bl-bu 2 2 1 1 bu-gr bu-gr 16 16
M
DV/2
DV/2
-X38
-X38
bl-rd 27 27
wh-br 39 39
gn-or 21 21
wh-bu 28 28
bl-bu 5 5
DS/44
-X18
-F4
4
4
1 10A 2
bl-bu 1 2 ye-rd
FJ/2
FJ/2
-X4
-X4
5
5
-F3
/2.A1
-A12
6
6
1 10A 2
bu-or 1 2 ye-rd
FJ/2
FJ/2
-X3
-X3
bl-bu 11 11
wh-bu 12 12
gn-or 17 17
wh-br 20 20
4 bl-rd bl-rd 10 10
-X295
AP/6
br-pu 8 8
19 19
7
bu-or
br br 35 35
br br 36 36
DT/36
-X21
-M60
1 1 rd rd 30 30
2 2 gn gn 29 29
3 3 bl bl 24 24
M
4 4 bu-br bu-br 31 31
5 5 wh-gn wh-gn 14 14
6 6 wh-rd wh-rd 16 16
7 7 wh-or wh-or 15 15
8 8 bu bu 13 13
8
8
br
or
FK/8
DR/8
DT/36
-X39
-X21
h /8.F1
c /10.F1
7/10
401233-01
A
F
B
D
Components:
A11 EFI control unit
A12 EPT control unit
F2 Fuse
F3 Fuse
F4 Fuse
M13 Fuel pump
M60 Motor drive
P10 Combination instrument
X295 Diagnostics connector
1 2 3 4 5 6 7 8
401234-01
-A11 -P10
/7.A3 /7.A1
A /9.A1 /9.A7 A
17
18
12
25
42
22
41
CZ/3 CY/3
3
2
1
DS/44 DS/44 DS/44 DS/44 DS/44 DS/44
41
18
12
42
17
25
22
1
2
3
3
-X62 -B70
wh-pu
gn-rd
rd-gr
bl-or
bl-gr
lbu
or
bl
B B
wh-pu
gn-rd
rd-gr
bl-or
bl-gr
lbu
C -X45 C
-X40 -X42 -X43 -X48 FS/4
4
2
DF/2 DW/2 DQ/2 FM/1
2
1
DY/4
1
2
4
2
3
1
1
DF/2 DW/2 DQ/2 FL/1
1
1
2
2
D -X40 -X42 -X43 -X44 FS/4 D
1
3
-X45
or
or
or
or
or
or
bl
bl
WIRING DIAGRAM
bl i /9.E1
/7.F8 h or
F F
690 Enduro R 09/10/11
26.8 8/10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 207
Components:
A11 EFI control unit
B51 Lambda sensor (cylinder 1)
B70 Front wheel speed sensor
M20 Fuel evaporation valve (USA version only)
M21 Secondary air valve
M51 Injector (cylinder 1)
P10 Combination instrument
R51 Ignition coil (cylinder 1)
1 2 3 4 5 6 7 8
401235-01
-A11 -P10
/8.A1 /8.A7
A /10.A1 /10.A7 A
15
13
10
26
34
11
32
31
4
DO/8
6
DS/44 DS/44 DS/44 DS/44 DS/44 DS/44 DS/44
11
31
32
15
13
10
26
4
34
6
-X63
wh-pk
ye-gn
ye-or
ye-br
bl-gn
bl-gn
bu
pk
rd
gr
B B
wh-pk
ye-gn
ye-or
ye-br
bl-gn
pk
rd
gr
C -X49 -X50 C
AR/3 -X51 -X16 -X35 -X36 AM/3
3
3
2
1
AP/6 CM/2 FT/3 FT/3
5
2
AM/3 AR/3
1
1
2
3
3
2
2
5
2nd
3rd
t°
N
AM/3
3
3
6
4
2
1
1
1
3
3
6
4
-X49
bu
bu
bu
bu
bu
bl
bl
bl
bl
bl
WIRING DIAGRAM
/8.E8 i bl bl i /10.E1
F F
690 Enduro R 2011
26.9 9 /10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 209
Components:
A11 EFI control unit
B10 Throttle position sensor circuit A
B12 Intake air temperature sensor
B26 Rollover sensor
B30 Side stand switch
B31 Accelerator position sensor
B34 Gear position sensor
P10 Combination instrument
1 2 3 4 5 6 7 8
401236-01
-A11 -P10
/9.A1 /9.A7
A A
14
35
20
23
24
33
36
38
44
2
DO/8 DO/8
7
5
8
DS/44 DS/44 DS/44 DS/44 DS/44 DS/44
2
14
20
23
24
35
33
36
38
44
7
5
8
-X63 -X63
wh-ye
ye-bu
gn-gr
bu-or
br-rd
bl-ye
bl-br
wh
wh
pu
ye
br
br
B B
wh-ye
ye-bu
gn-gr
bu-or
br-rd
bl-ye
bl-br
pu
ye
2
1
1
DP/3 DX/3 DV/2 EC/3
3
3
2
1
AT/2 AT/2 AL/2
1
1
1
2
2
2
3
3
-B13 -B41 -B38 -B37 -S55 -B21 t° t° -B32
R R
p p
AT/2 AL/2
3
2
2
1
1
DP/3 DX/3 DV/2 EC/3
1
1
2
2
3
2
-X54 -X56
bu
bu
br
br
br
br
br
bl
bl
bl
WIRING DIAGRAM
/9.E8 i bl
/7.F8 c br
F F
26.10
690 Enduro R 09/10/11
10/10
26
1 2 3 4 5 6 7 8
26 WIRING DIAGRAM 211
Components:
A11 EFI control unit
B13 Ambient air pressure sensor
B21 Engine coolant temperature sensor (cylinder 1)
B32 Fuel level indicator
B37 Crankshaft position sensor
B38 Clutch switch
B41 Manifold absolute pressure sensor (cylinder 1)
P10 Combination instrument
S55 Map‑Select Switch
Cable colors:
bl Black
br Brown
bu Blue
gn Green
gr Gray
lbu Light blue
or Orange
pk Pink
pu Violet
rd Red
wh White
ye Yellow
Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
−49 °F) 50 % distilled water
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean
Fuel additive
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Fuel Stabilizer
Long-life grease
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Bike Grease 2000
Lubricant (T158)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmogrease® PP 300
Lubricant (T511)
Guideline
– KTM recommends Lubcon® products.
Supplier
Lubcon®
– Turmsilon® GTI 300 P
Lubricant (T159)
Guideline
– KTM recommends Bel‑Ray® products.
Supplier
Bel‑Ray®
– MC‑11®
Lubricant (T625)
Guideline
– KTM recommends Molykote® products.
Supplier
Molykote®
– 33 Medium
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.
Supplier
Motorex®
– Clean & Polish
Bearing puller
Art. no.: 15112017000
400037-01
400125-01
Bleed syringe
Art. no.: 50329050000
400058-01
400059-01
Extractor
Art. no.: 58429009000
400073-01
400082-01
Mounting sleeve
Art. no.: 58529005000
400095-01
400101-01
400104-01
Extractor
Art. no.: 59029033000
400105-01
Feeler gauge
Art. no.: 59029041100
35
30
25
20
15
12
10
5
400110-01
400142-01
400085-01
Testing hose
Art. no.: 61029093000
201314-01
400149-01
200306-01
Work stand
Art. no.: 62529055000
400151-01
400153-01
400154-01
400156-01
Extractor
Art. no.: 75029021000
400157-01
Assembly screws
Art. no.: 75029033000
400158-01
400160-01
400161-01
Push-in drift
Art. no.: 75029044010
500163-01
Push-in drift
Art. no.: 75029044020
500162-01
400185-01
400186-01
400187-01
Extractor
Art. no.: 75029048000
400162-01
Clamping plate
Art. no.: 75029050000
400163-01
Push-out drift
Art. no.: 75029051000
400164-01
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
400170-01
400176-01
400177-01
400181-01
500165-01
Hook wrench
Art. no.: T106S
301085-01
Depth micrometer
Art. no.: T107S
300577-10
Pin
Art. no.: T120
201235-10
Pressing tool
Art. no.: T1206
200583-10
Pressing tool
Art. no.: T1207S
200585-01
Vacuum pump
Art. no.: T1240S
200273-10
Pressing tool
Art. no.: T129
200584-01
Protecting sleeve
Art. no.: T1401
200635-10
Clamping stand
Art. no.: T14015S
200733-10
Clamping stand
Art. no.: T14016S
200688-10
Gripping tool
Art. no.: T14026S1
200639-10
Assembly tool
Art. no.: T1402S
200634-10
Open-end wrench
Art. no.: T14032
200640-10
Clamping stand
Art. no.: T1403S
200637-10
Mounting sleeve
Art. no.: T1515
300569-10
300574-10
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. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
Side cover
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spark plug connector
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starting procedure
for making checks . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
T
Tap compression
fork legs, assembling . . . . . . . . . . . . . . . . . . . . . . . . 24
fork legs, disassembling . . . . . . . . . . . . . . . . . . . . . . 22
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 184
clectrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 182
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
engine - tolerance, wear limits . . . . . . . . . . . . . . . . . 178
engine tightening torques . . . . . . . . . . . . . . . . . . . . 180
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . 187
Wiring diagram . . ........................ 192-211
page 01 of 10 ........................ . . . . 192
page 02 of 10 ........................ . . . . 194
page 03 of 10 ........................ . . . . 196
page 04 of 10 ........................ . . . . 198
page 05 of 10 ........................ . . . . 200
page 06 of 10 ........................ . . . . 202
page 07 of 10 ........................ . . . . 204
page 08 of 10 ........................ . . . . 206
page 09 of 10 ........................ . . . . 208
page 10 of 10 ........................ . . . . 210
Work rules ................................... 6
10/2012
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria Photo: Mitterbauer/KTM
http://www.ktm.com