Home

Kenmore 596.58642 Refrigerator User Manual

1. Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Remove the seat P 102 MAINTENANCE WORK ON CHASSIS AND ENGINE 104 m Disconnect the negative minus cable of the battery Pull off connector in an upward direction Remove screws Pull retaining bracket of the battery forward and remove it Take off the positive terminal cover O Disconnect the positive plus cable of the battery Press the wiring harness to one side and pull the battery out of the battery rack e Info I Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components can safety equipment can be damaged The vehicle is then no longer safe to ride Slide the battery into the battery rack e Info The battery terminals must be at the rear Attach the positive cable and mount positive terminal cover Position retaining bracket Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7
2. Specification KTM recommends Motorex products Supplier Motorex Long Therm 2000 Specification KTM recommends Motorex products Supplier Motorex Moto Clean 900 Specification KTM recommends Motorex products Supplier Motorex Chain Lube 622 Specification KTM recommends Motorex products Supplier Motorex Joker 440 Universal STANDARDS 171 Different technical development directions required a new specification for 4 stroke motorcycles the JASO T903 MA Standard Ear lier engine oils from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specification Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the oil as the engine The JASO MA Standard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos ity The viscosity describes only one property of oil and says nothing about quality INDEX 172 A Braking a o deo dus al k MD eer A 48 Air filter C unda PET PCS 120 Chain FEMOVING Sek Geen EATEN RUM S ada ONE 119 Checking ditt asa p ero thu EE HEUS 69 Antifreeze checking wear KK KI KI KIRI K KI KI KI K
3. 149 Checking headlamp Setting ooocccccccnccoccncconnononcncnacnnnon 118 Conservation for winter operation UU 149 Adjusting the headlight range oocccoccnccocnncononononcncnncnnnnn 119 STORAGE 0000 dnd 150 Removing the air filter J eee ee 119 JULI m M CT 150 Installing the air filter J eee 120 Putting into operation after storage 151 Coolifig Sysle mosse See E Dee e teet ke e Dd tui 121 TECHNICAL DATA ENGINE kk 152 Checking the antifreeze and coolant level 122 Capacity engine oline Ta 153 Checking the coolant level eeeee 124 Capacity coolant sss 153 Draining coolant 8 cone eee tenetis 126 TECHNICAL DATA ENGINE TIGHTENING TORQUES 154 Filling the cooling system X 127 TECHNICAL DATA CHASSIS nennen 157 Adjusting basic position of Clutch levef j lj_L U 129 Lighting equipment A E 158 Checking correcting fluid level of hydraulic clutch 129 Capacity TU E ley nan tete a a a 159 Checking play in gas Bowden cable 130 TECHNICAL DATA FORK nennen 160 Adjusting play in gas Bowden cable amp 131 TECHNICAL DATA SHOCK ABSORBER nennen 161 Removing the engine guard Ak 132 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 163 Installing the engine guard A ii kk 132 SUBSTANCES Emere rere rere 166 AUXILIARY SUBSTANCES rrna makan nia
4. Check that leaf spring O in the brake caliper and sliding plate in the brake caliper support are seated correctly Insert the brake pads insert the bolt and mount the split pin Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Adjust the brake fluid level to level Q Specification Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 P 166 Position the cover with the membrane Mount and tighten screws e Info Clean up overflowed or spilt brake fluid immediately with water MAINTENANCE WORK ON CHASSIS AND ENGINE Checking free play of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Specification Free play at foot brake lever 3 5 mm 0 12 0 2 in e Info You will know that contact has been made with the foot brake cylinder piston when there is increased resistance when you activate the foot brake pedal 100256 10 Ifthe free travel does not meet specifications Adjust the basic position
5. 100199 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 133 e Info The engine oil level must be checked when the engine is at operating temperature Stand the motorcycle upright on a horizontal surface Condition The engine is at operating temperature Check the engine oil level e Info After switching off the engine wait for one minute and then check The engine oil must be between the lower and upper edge of the oil level viewer Ifthe engine oil level is not at the specified level Top up the engine oil 7 P 140 Drain the engine oil X P 134 Remove the oil filter X P 135 Clean oil screens X P 137 Mount the oil filter P 137 Fill up with engine oil 4 P 139 100210 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 134 Draining engine oil X Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info Drain the engine oil only when the engine is warm Remove the engine guard P 132 Place a suitable container under the engine Remove the oil drain
6. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir Ifthe fluid level reaches the MIN marking Top up the brake fluid of the rear brake X P 87 Topping up brake fluid of rear brake X Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 b
7. TECHNICAL DATA SHOCK ABSORBER Shock absorber part number 15 18 7D 11 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Spring preload 19 mm 0 75 in Spring rate Weight of rider 75 85 kg 165 187 Ib 80 N mm 457 Ib in Spring length 220 mm 8 66 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 80 90 mm 3 15 3 54 in TECHNICAL DATA SHOCK ABSORBER Fitted length 395 mm 15 55 in TECHNICAL DATA CHASSIS TIGHTENING TORQUES Remaining screws chassis M5 4 Nm 3 Ibf ft Spoke nipple front wheel M5 4 Nm 3 Ibf ft x Spoke nipple rear wheel M5 4 Nm 3 Ibf ft Screw exhaust heat shield M5 8 Nm 5 9 Ibf ft Screw electrical holder M5 3 Nm 2 2 Ibf ft Screw footbrake pedal foothold M5 6 Nm 4 4 Ibf ft Loctite 243 Screw fuel pump M5 6 Nm 4 4 Ibf ft Screw fuel level indicator M5 3 Nm 2 2 Ibf ft Screw side cover M5 2 Nm 1 5 Ibf
8. kK KK KK KK KK KK 85 Engine characteristic checking free play KE ee oo 85 adjusting A A WA Se Kw AA AS 111 lj WT LIP M 57 Engine guard Adjusting compression damping ls 57 tal dard D n c eode Ka e iota ER ted 132 Adjusting rebound lisse 58 YeEMOV Ng De ehe HH 132 Bleeding fork legs KRI KIRI eee 62 INDEX 174 Fork part number LL LL LV KK KK KK KK KIRI ee 18 HOM ste nes Docet ons did Kel UC erue deals 22 23 Fork protector ere erry positioning ee eee KK KK KK KK nn 64 Ignition loek een 24 IONES Be a ESA EEE RA A na itg 64 Indicator lights 2 00 eR 26 en CA A Be bade ne Hd 94 AN EKE N N M N sare v 92 Key number A 5 2 28 Ave ak a A 17 Fuel oils ete MM N J DMDNHNHNHNDMDMDMDDDDDMDXNNA y a EEE Fase Light switch ederent re 20 of individual power consumer changing 109 Loading the vehicle KK eee 40 Hand brake lever ooo ooooooooooonmomooo 19 aoe 107 adjusting free travel kK KK KK K RIK KI RIK eee 77 a c Do KAK OM AD O checking free play 0 kk kk kk RI 76 Maintenance 1 3 5 lt a a lal nee ea 8 Handlebar angle Motorcycle adj sting ica gen een 67 cleaning e 147 Handlebar position llle 67 jacking d cR PAPE d 50 ECC A O AR 68 removing from the work stand o o o o o oooooo o 56 Handrails es dene MA Headlight Oil filter Adjusting the light range vs ns 119 changing ROE BE
9. spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor Capacity engine oil Engine oil 1 70 1 8 qt Engine oil SAE 10W 60 P 167 Capacity coolant Coolant 1 20 1 27 qt Coolant P 166 Coolant mixed ready to use P 166 TECHNICAL DATA ENGINE TIGHTENING TORQUES 154 Plug oil bore self tapping 9 Nm 6 6 Ibf ft Loctite 243 Screw membrane fixation M3 2 5 Nm 1 84 Ibf ft Loctite 243 Oil jet conrod lubrication M4 2 Nm 1 5 Ibf ft Loctite 243 Hose clamp intake flange M4 1 5 Nm 1 11 Ibf ft Screw cover plate for oil return line M5 6 Nm 4 4 Ibf ft Screw breather cover on valve cover M5 3 Nm 2 2 Ibf ft Loctite 2437 Screw gear sensor M5 5 Nm 3 7 Ibf ft Loctite 243 Screw clutch spring M5 6 Nm 4 4 Ibf ft Locking screw for bearing M5 6 Nm 4 4 Ibf ft Loctite 648 Screw oil filter cover M5 6 Nm 4 4 Ibf ft Screw oil pump cover M5 6 Nm 4 4 Ibf ft Loctite 2437 Oil jet piston cooling M6x0 75 4 Nm 3 Ibf ft Loctite 2437 Screw locking lever M6 10 Nm 7 4 Ibf ft Loctite 243 Screw Autodecompression M6 3 4 Nm 2 2 3 Ibf ft Loctite 243 Screw axial lock of camshaft
10. Shift gear to neutral Switch off the ignition by turning the ignition key in the position amp e Info I If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a hard surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it RIDING INSTRUCTIONS 51 Lock the steering by moving the handlebar to the left pressing down the ignition key in the position and turning it to the position A To make locking the steering easier move the handlebar a little to the left and right Remove the ignition key Refueling Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of 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
11. 32 Fork part n m beroen oiera aen a nnns 18 Opening filler Ga iie add 33 Shock absorber part number sssseee e 18 Glosing fillercapss d e ti etr rte ia 33 OPERATING ELEMENTS lkae kaka kk kK KAKA 19 Handrailsu oi cete nina tada daa 34 Cl telileVer c Eur a on ee Eka e DE och con e ELA 19 Seat release Lui dirias 34 Hand brake deveras torte er ce b n teta 19 O e 35 Light Switch er meto se t e reis tec CC eae 20 Shift levet dec doe tit dee oot e oni e vate so ded 35 Light switch ee ee tt e eie Mid tede 20 Foot brake pedal sss 36 Headlight flasher SW tC kk kez 21 SIE SER yy eee ca pee eco the rr ra sea e a e erre bun 37 PlaSh reswit Hite io oot tee a et 21 GENERAL TIPS AND HINTS ON PUTTING INTO ST ua arten Cors vc n anl lA eats 25 OPERATION xcci dde erts aan 38 Ha ro eto te et ER Need 22 Advice on first use eise oi 38 HORN ies sn DES 23 Running in the engine tenentes 40 Emergency OFF switch 23 Load ng the vehlcle ster ad reete E heeded 40 Electric starter button au 24 RIDING INSTRUCTIONS snra a emen 42 Ignition steering lock 24 Checks before putting into operation 42 Combination instrument keke 25 STATING zy ee 43 Combination instrument function buttons 25 Star U Di xal an o tis tect ee teat heey 45 Combination instrument tachometer cececeececeeeeee 26 Shifting TIOS d dock cle tacos dt 45 Combination
12. JASO T903 MA P 171 SAE P 171 SAE 10W 60 Specification Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T according to SAE P 171 SAE 5 Specification Use only oils that comply with the specified standards see specifications on the container and that possesses the corresponding prop erties KTM recommends Motorex products Supplier Motorex Racing Fork Oil according to ISO VG 15 SUBSTANCES 168 Specification Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Super unleaded ROZ 95 RON 95 PON 91 according to DIN EN 228 ROZ 95 RON 95 PON 91 AUXILIARY SUBSTANCES B Specification KTM recommends Motorex products Supplier Motorex Chain Clean 611 Specification KTM recommends Motorex products Supplier Motorex Protect amp Shine 645 Specification KTM recommends Motorex products Supplier Motorex Accu Contact Specification KTM recommends Motorex products Supplier Motorex Moto Polish AUXILIARY SUBSTANCES
13. Minimum thickness Q gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the front brake linings A P 81 100255 10 Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop MAINTENANCE WORK ON CHASSIS AND ENGINE A A gt Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they
14. KI KIR KK KI KK 74 checking Arsen ae ae dat 122 Cleaning ara re as eV AA 69 B Chain guide Baggage 0 DD NE DY A DD 40 adjusting cou tds a Avde ded dudl eet eg arab towed 75 Battery Chain tension A PEINT PON 104 adjusting eee ees 71 recharging sees e aaa 105 checking KK KHK KK KK nnn 70 A Atk a sd sh lA VR 103 Chassis number 20 0 0 16 Brake discs Checking headlamp setting 118 checking a do 75 Cleaning lt Pm 147 148 Brake fluid Clutch adding brake fluid for front brake 0 0 ee eee 78 checking correcting fluid level 129 of rear brake adding llle 87 Clutch levet a 4 A3 Da En aan 19 Brake fluid level adjusting basic position o oooooooooooooo 129 Checking the front brake brake fluid level 78 Combination instrument lt lt 200 eee eee 25 of rear brake checking llle 86 Coolant temperature indicator o o oooooo 32 Brake linings XL a kk kk kk kK KK KK KK KK KK KK KK KK kk 80 Display LA kK KK ee 27 changing for rear brake 22 22m 89 Display ODO KK KK KK KK KK nn 30 Changing the front brake linings 81 DisplayTRIPF we eee nne 32 of front brake checking 22 2222 81 Function buttons oo 25 of rear brake checking 89 ee pierin o sire e mice d y Ee r ast iet ius 2 etting kilometers or miles VR KK KV KK Brakes ES poude pt OS 48 S
15. Plug oil thermostat M24x1 5 15 Nm 11 1 Ibf ft TECHNICAL DATA CHASSIS 157 Frame Lattice frame made of chrome molybdenum steel tubing powder coated Fork WP 4860 MXMA Shock absorber WP Suspension 4618 with Pro Lever deflector Suspension travel front 250 mm 9 84 in Rear 250 mm 9 84 in Brake system front Disc brake with dual piston brake caliper floating Rear Disc brake with single piston brake caliper floating Diameter of brake discs front 300 mm 11 81 in Rear 240 mm 9 45 in Wear limit of brake discs front 4 5 mm 0 177 in Rear 3 5 mm 0 138 in Tire air pressure road solo front 1 8 bar 26 psi Rear 1 8 bar 26 psi Tire air pressure with passenger fully loaded front 2 0 bar 29 psi Rear 2 2 bar 32 psi Tire air pressure offroad single rider front 1 5 bar 22 psi Rear 1 5 bar 22 psi TECHNICAL DATA CHASSIS Rear wheel gearing 15 45 Chain 5 8 x 1 4 X ring Steering head angle 63 Wheelbase 1 498 15 mm 58 98 0 59 in Seat height unloaded 910 mm 35 83 in Ground clearance unloaded 300 mm 11 81 in Weight without fuel 138 5 kg 305 3 Ib Maximum permissible front axle load 150 kg 331 Ib Maximum permissible rear axle load 200 kg 441 Ib Maximum permissible overall
16. rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Warning Environmental 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 e Info This motorcycle is equipped with a regulated catalyst Leaded fuel will destroy the catalyst You should therefore use unleaded fuel only RIDING INSTRUCTIONS 100240 10 switch off engine Open the filler cap P 33 Fill the fuel tank with fuel up to measurement Specification Measurement of 20 mm 0 79 in Fuel tank content 12 1 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 P 168 Close the filler cap P 33 Press the SET function button for 2 seconds Y The fuel level warning lamp O switches off TRIP F is set to O and appears in the previous display mode e Info If you do not press the SET function button the reset takes place automati cally after about 3 minutes GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop Engine Change engine oil and oil filter clean oil screens X P 133 K10N K50A K100A J1A Check and adjust valve clearance 4 Check engine moun
17. 104 Set the clock P 29 Fill up with fuel P 51 Carry out checks before putting into operation P 42 Make a test ride TECHNICAL DATA ENGINE Design 1 cyliner 4 stroke engine water cooled Displacement 654 cm 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 Pressure circulation lubrication with 2 rotor pumps Primary transmission 36 79 Clutch APTC antihopping clutch in oil bath hydraulically actuated Gearbox 6 gears claw shifted Transmission ratio 1st gear 14 35 2nd gear 16 28 3rd gear 21 28 Ath gear 21 23 5th gear 23 22 TECHNICAL DATA ENGINE 6th gear 23 20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12V 224 W Spark plug NGK LKAR 8Al 9
18. 18 4 Ibf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 Ibf ft Screw engine bearer on frame M10 45 Nm 33 2 Ibf ft Screw side stand M10 35 Nm 25 8 Ibf ft Loctite 243 Lambda probe M12x1 25 24 5 Nm 18 07 Ibf ft Screw swingarm pivot M12x1 75 80 Nm 59 Ibf ft Nut linkage lever to rocker arm M14x1 5 100 Nm 73 8 Ibf ft Nut linkage lever on swingarm M14x1 5 100 Nm 73 8 Ibf ft Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Screw bottom steering head M20x1 5 60 Nm 44 3 Ibf ft Loctite 243 Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft SUBSTANCES B according to DOT Specification Use only brake fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Castrol and Motorex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Specification Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze 25 45 C 13 49 F 50 Anti corrosion antifreeze 50 distilled water Antifreeze 40 C 40 F Supplier Motorex Anti Freeze SUBSTANCES E according to
19. 4 Ibf ft Plug in connector O Attach the minus cable Mount the seat P 103 MAINTENANCE WORK ON CHASSIS AND ENGINE Set the clock P 29 Recharging the battery A Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even if there is no load on the battery it loses power every day The charge state and the type of charge are very important for the service life of the battery Fast recharging with a high charge current shortens the battery s service life If the charge current the charge voltage and the char
20. ER N u a eiut fcn 133 Headlight bulb changing o ooo coco 115 ALL paese iake ota i pee dedit deti este ad Headlight flasher switch gt o oo zi A dU AK ts Headlight mask with headlight oll en fitting Ban Se wall Mn N NH HHMJJMM AMAMMMA 114 O E FEMOVIN Ged s gotta A reg ek Dn ges 113 INDEX 175 Oil screens S leaning veredas a ai aa ke tas eas 137 Seat OWNER S MANUAL MOURNE a ares Aa 103 Basics coco 10 LETMDWINB a ee een 102 P Seat release os na tabu lun te Dad ems 34 Parking RR ada 49 Shift levei 2 3 20 2 20 weed ERAT ORARE ERE 35 Parking light bulb Shifting hz buceo A sala hun Quah A as 45 Changing Vaciar eed tLe CC een 116 Shock absorber ees 57 Passenger footrests 2 222222 esses 35 adjusting rebound damping eee 8 62 Play in gas Bowden cable compression damping general videi aad t Ni erts 59 adjusting 131 compression damping high speed adjusting 60 DT MACRO PENES 130 compression damping low speed adjusting 59 TM Shock absorber part number 18 Putting into operation Side stand 37 Advice on first Use on 38 RS SER A A ud DE RAO Er 9 pO NEHME UCM MU M 151 pare parts accessories o o oo oo een Checks before putting into operation 42 Spoke tension R CHECKING uds Peis i crate ee P E ERN re dat a 101 Starting uu D redeo e don ede ite ak sar ee 43 Rear hub rubber dampers St
21. Loctite 2437 Plug crankshaft location M8 20 Nm 14 8 Ibf ft Screw unlocking of timing chain ten M10x1 10 Nm 7 4 Ibf ft sioner Plug drain hole of water pump M10x1 15 Nm 11 1 Ibf ft Plug oil bore for oil radiator M10x1 15 Nm 11 1 Ibf ft Plug oil bore M10x1 15 Nm 11 1 Ibf ft Loctite 243 TECHNICAL DATA ENGINE TIGHTENING TORQUES Screw cylinder head M10 Tightening sequence lubricated with engine oil Tighten diagonally beginning with the rear screw on the chain shaft Step 1 15 Nm 11 1 Ibf ft Step 2 30 Nm 22 1 Ibf ft Step 3 45 Nm 33 2 Ibf ft Step 4 60 Nm 44 3 Ibf ft Spark plug M12x1 25 17 Nm 12 5 Ibf ft Coolant temperature sensor on cylinder M12x1 5 12 Nm 8 9 Ibf ft head Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 Ibf ft Plug oil bore M14x1 5 15 Nm 11 1 Ibf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 Ibf ft Loctite 243 Ignition rotor nut M18x1 5 100 Nm 73 8 Ibf ft Nut engine sprocket M20x1 5 60 Nm 44 3 Ibf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 Ibf ft Loctite 243 Nut primary gear M20LHx1 5 100 Nm 73 8 Ibf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft Plug timing chain tensioner M20x1 5 25 Nm 18 4 Ibf ft Screw in generator cover M24x1 5 8 Nm 5 9 Ibf ft
22. Nm 18 4 Ibf ft Screw front brake caliper M8 25 Nm 18 4 Ibf ft Loctite 2437 Screw main silencer holder M8 25 Nm 18 4 Ibf ft Screw main silencer holder on fuel tank M8 25 Nm 18 4 Ibf ft Loctite 2437 Screw rear footrest bracket M8x16 25 Nm 18 4 Ibf ft Screw front footrest bracket M8 25 Nm 18 4 Ibf ft Screw spring holder on side stand M8 25 Nm 18 4 Ibf ft Loctite 243 bracket Screw top triple clamp M8 17 Nm 12 5 Ibf ft Screw bottom triple clamp M8 12 Nm 8 9 Ibf ft Screw fork stub M8 15 Nm 11 1 Ibf ft Screw steering stem M8 20 Nm 14 8 Ibf ft Loctite 243 Screw handrail M8 20 Nm 14 8 Ibf ft Screw license plate holder top M8 20 Nm 14 8 Ibf ft Screw fuel tank top M8 25 Nm 18 4 Ibf ft Loctite 243 Screw fuel tank bottom M8 25 Nm 18 4 Ibf ft TECHNICAL DATA CHASSIS TIGHTENING TORQUES Screw handlebar clamp M8 20 Nm 14 8 Ibf ft Loctite 243 Screw side stand bracket M8 25 Nm 18 4 Ibf ft Screw connection lever on frame M8 30 Nm 22 1 Ibf ft Remaining nuts chassis M10 50 Nm 36 9 Ibf ft Remaining screws chassis M10 45 Nm 33 2 Ibf ft Engine carrying screw M10 45 Nm 33 2 Ibf ft Loctite 243 Screw top shock absorber M10 45 Nm 33 2 Ibf ft Loctite 243 Screw bottom shock absorber M10 45 Nm 33 2 Ibf ft Loctite 243 Screw foot brake pedal M10LH 25 Nm
23. P 69 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and polishing materials for metal rubber and plastic P 169 Treat all painted parts with a mild paint polish High luster polish for paint P 169 To prevent electrical problems treat electric contacts and switches with contact spray Contact spray P 169 Oil the ignition steering lock Universal oil spray P 170 CONSERVATION FOR WINTER OPERATION 149 Conservation for winter operation Info e If you use the motorcycle in winter you must expect salt on the roads You should therefore take precautions against aggressive road salt If you have ridden the vehicle on salted roads clean it with cold water Warm water would reinforce the effect of the salt Clean the motorcycle P 147 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance e Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Clean the chain P 69 STORAGE Storage Info If you want to garage the motorcycle for a longer period take the following actions Before storing the motorcycle check all parts
24. comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container MAINTENANCE WORK ON CHASSIS AND ENGINE 83 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove the cover 6 with membrane 6 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons Ensure that brake fluid does not overflow from the brake fluid reservoir and suction it off if necessary e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove split pin O remove bolt O toward the right by striking it and remove the brake linings Clean brake caliper and brake caliper support Check parts for damage and wear Replace damaged or worn parts 100290 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 84 400418 10
25. filters fuel cleaning substances brake fluid batteries etc according to regulations e Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocycle seal the exhaust system to prevent penetration by water First remove coarse dirt particles with a gentle water spray Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner P 170 e Info Use warm water containing normal motorcycle cleaner and a soft sponge If you have ridden the vehicle on salted roads clean it with cold water Warm water would reinforce the effect of the salt After rinsing the motorcycle thoroughly with a soft jet of water dry it with compressed air and a cloth CLEANING 148 Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up and then apply the brakes e Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate Push back the protection covers on the handlebar instruments to allow water to evaporate After the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain
26. for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle P 147 Change engine oil and oil filter clean oil screens 4 P 133 Check the antifreeze and coolant level P 122 Checking the tire air pressure P 100 Remove the battery A P 103 Recharge the battery X P 105 Specification Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place should be dry and not subject to large temperature differences e Info KTM recommends jacking up the motorcycle Jack up the motorcycle P 56 STORAGE Cover the motorcycle with a porous sheet or blanket Info e Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Putting into operation after storage Remove the motorcycle from the work stand P 56 Recharge the battery 4 P 105 Install the battery A P
27. free travel does not meet specifications Adjust the free travel of the handbrake lever P 77 Adjust the free travel of the handbrake lever with the adjustment screw O e Info Turn the adjustment screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Check the free play of the hand brake lever P 76 MAINTENANCE WORK ON CHASSIS AND ENGINE 78 Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop The brake fluid level must not fall below the center of the level viewer when the brake fluid reservoir is vertical Ifthe brake fluid level is lower than the center of the level viewer Add brake fluid for the front brake X P 78 Warning Danger of accidents Brake system failure MINIf the brake f
28. ft Screw headlight mask M5 5 Nm 3 7 Ibf ft Screw side stand switch M5 3 Nm 2 2 Ibf ft Screw seat lock M5 3 Nm 2 2 Ibf ft Loctite 222 Screw starter cable on starter M5 3 Nm 2 2 Ibf ft Nut foot brake cylinder screw M6 10 Nm 7 4 Ibf ft Remaining nuts chassis M6 15 Nm 11 1 Ibf ft Remaining screws on fuel tank M6 6 Nm 4 4 Ibf ft Remaining screws chassis M6 10 Nm 7 4 Ibf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 Ibf ft Screw rear brake disc M6 14 Nm 10 3 Ibf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 Ibf ft Loctite 243 Screw license plate holder bottom M6 8 Nm 5 9 Ibf ft Screw ball joint of push rod on foot M6 10 Nm 7 4 Ibf ft Loctite 243 brake cylinder Screw radiator bracket M6 5 Nm 3 7 Ibf ft TECHNICAL DATA CHASSIS TIGHTENING TORQUES 164 Screw magnetic holder on side stand M6 10 Nm 7 4 Ibf ft Loctite 243 Screw voltage regulator rectifier M6 8 Nm 5 9 Ibf ft Screw SLS valve M6 4 Nm 3 Ibf ft Screw ignition lock M6 10 Nm 7 4 Ibf ft Loctite 2437 Nut rear sprocket screw M8 35 Nm 25 8 Ibf ft Loctite 2437 Nut manifold on cylinder head M8 25 Nm 18 4 Ibf ft Copper paste Remaining nuts chassis M8 30 Nm 22 1 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw exhaust clamp on main silencer M8 25
29. grease on the glass will evaporate by the heat and be deposited on the reflector Remove the headlight mask with the headlight P 113 Remove rubber cap O MAINTENANCE WORK ON CHASSIS AND ENGINE 600612 10 Changing the flasher bulb Note Pull bulb socket out of the reflector Pull parking light bulb out of the bulb socket Check parts for damage and wear Replace damaged or worn parts Insert a new parking light bulb into the bulb socket Parking light W2 1x9 5d P 158 Insert the bulb socket into the reflector Insert the rubber cap Refit the headlight mask with the headlight P 114 Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the glass will evaporate by the heat and be deposited on the reflector 100301 10 Remove the screw on the rear of the flasher housing Carefully swing the diffuser O forwards and remove it Lightly pinch the orange cap at the holding points and remove it Press the flasher bulb carefully into the holder turn it about 30 counterclockwise and remove it from the holder e Info Do not touch the reflector with your fingers and try to avoid contact with oil or grease Check parts for damage and wear Replace damaged or worn parts MAINTENANCE WORK ON CHASSIS AND ENGINE 118 Press the new flasher bulb carefully into the holder a
30. instrument control lamps 26 Brakin gi nan Fen me kl hey k H ay carac ek ee air carnes 48 CONTENTS 4 Stopping PArkiN8 ccocccccoccoconcncnnnnnnnnnncnncnnnoncnonnnnonnnnononona 49 Cleaning the ChalN ooccccoccncconcncncnncnncnncnnnnnnoncnnnnnnnnnnenonnnnns 69 Refueling cd vc eie A a ee uade odds 51 Checking the chain tension c cccccsececcaeeceeeeeeeeeeeesaeeees 70 GREASING AND SERVICE TABLE M K kk kk k 53 Adjusting chain tensSion cccccccccsscceseeeeeaseceseeeeeeneeesaeees 71 Important maintenance work to be carried out by an Checking rear sprocket engine sprocket for wear 73 authorized KTM workshop sm 53 Checking chain wear 74 Important maintenance work to be carried out by an Adjusting chain guide V i n 75 authorized KTM workshop as additional order 95 Checking brake discs eke kek k ye 75 MAINTENANCE WORK ON CHASSIS AND ENGINE nn 56 Checking free play of hand brake lever 76 Jacking up the motorcycle kk 56 Adjusting free travel of handbrake lever 77 Removing the motorcycle from the work stand 56 Checking front brake fluid level eeees 78 Fork shock absorber ais ION 57 Adding brake fluid for front brake amp 78 Adjusting compression damping OF fork 9 Brake linings nto sados 80 Adjus
31. of environmental damage Read this owner s manual carefully and completely before making your first trip It contains a lot of information and tips to help you operate and handle your motorcycle Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle IMPORTANT NOTES T The owner s manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold VIEW OF VEHICLE 12 View of vehicle front left side 100234 10 VIEW OF VEHICLE Hand brake lever Clutch lever Handrail Filler cap Seat Front brake caliper Shift lever Engine number O 00 NI om AJOJ Nje Side stand Footrest H a m oO Seat release strap VIEW OF VEHICLE View of vehicle rear right side 100235 10 VIEW OF VEHICLE Ignition steering lock Rear mirror Light switch flasher switch horn Combination instrument Emergency OFF switch electric starter button Throttle grip Chassis number Rear brake caliper O 00 NI om AJOJ Nje Passenger footrest Shock absorber rebound damping Hij a m oO Foot brake pedal rA N Engine oil level viewer LOCATION OF SERIAL NUMBERS 1
32. plug 9 with the magnet and seal ring Completely drain the engine oil 100200 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 135 Thoroughly clean the oil drain plug with a magnet Check parts for damage and wear Replace damaged or worn parts Refit the oil drain plug with the magnet and seal ring and tighten it Specification Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft 100201 01 Removing the oil filter Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screws Remove oil filter cover with O ring Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 Remove screws Remove oil filter cover with O ring Pull the oil filter insert O out of the oil filter casing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area 100203 10 MAINTENANCE WO
33. ring and tighten it Specification Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft 100208 10 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove filler plug with O ring O from the clutch cover and add engine oil Engine oil 1 70 1 8 qt Engine oil SAE 10W 60 P 167 Refit plug with O ring and tighten it Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death De When running the engine always make sure there is sufficient ventilation EET and do not start or run the engine in a closed space Start the engine and check that it is oil tight Install the engine guard P 132 Check the engine oil level P 133 MAINTENANCE WORK ON CHASSIS AND ENGINE 140 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove filler plug with O ring O from the clutch cover and add engine oil Engine oil SAE 10W 60 P 167 Refit plug with O ring and tighten it Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation a 1002010 and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil leve
34. screws on left fork leg Push the fork protection downwards Remove the screws on the right fork leg Push the fork protection downwards Position the fork protection on the left fork leg Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the brake line and cable harness Put the clamp on mount and tighten screws O Position the fork protection on the right fork leg Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft 100292 11 MAINTENANCE WORK ON CHASSIS AND ENGINE Checking play of steering head bearing 4 Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play The steering head bearing play should be adjusted immediately in an authorized KTM workshop Info damaged after time If the bike is driven for a longer time with play in the steering head bearing the bearing and the bearing seats in the frame can be Jack up the motorcycle P 56 Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust play of the steering head bearing X P 66 Move the handlebar to and fro over the entire steering range The handlebar must b
35. table on the underside of the seat These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds e Info The hydraulic compression damping determines the fork suspension behavior Remove protection covers O Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs MAINTENANCE WORK ON CHASSIS AND ENGINE 58 Turn back counterclockwise the number of clicks corresponding to the fork type Specification Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Mount protection covers Adjusting rebound damping of fork e Info The hydraulic rebound damping determines the fork suspension behavior Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs 100244 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 59 Turn back counterclockwise the number of clicks corresponding to
36. the central position after use Vt To switch off the flasher light press the flasher switch towards the switch case The horn button is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position 500021 11 OPERATING ELEMENTS 23 The horn button is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position 100224 10 The emergency OFF switch is fitted on the left side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed 100225 10 OPERATING ELEMENTS 24 The electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated The ignition steering lock is located in front of the seat Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition
37. the front brake linings P 81 Check the rear brake linings P 89 Check brake system function Check the coolant level P 124 Check that all operating elements are correctly adjusted and free to move Check the functioning of the electrical equipment Check that baggage is correctly secured Siton the motorcycle and check the rear mirror setting RIDING INSTRUCTIONS 43 Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged 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 RIDING INSTRUCTIONS 44 Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key in the position Y After switching on the ignition you can hear the fuel pump working for about 2 seconds At the same time the combination instrument runs a function test Shift gear to neutral Y The green idling speed ind
38. weight 350 kg 772 Ib Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fuse 75011088015 15A Fuse 75011088010 10A Lighting equipment Headlight H4 P43t 12V 60 55 W Parking light W2 1x9 5d 12V 5W Instrument lights and indicator lamps LED Flasher light BA15s 12V 10 W TECHNICAL DATA CHASSIS Brake tail light LED Licence plate lamp W2 1x9 5d 12V 5W Front tire Rear tire 90 90 21 54 H TL Metzeler Enduro 3 Sahara 140 80 18 70 H TL Metzeler Enduro 3 Sahara For further information see the Service section under http www ktm com Capacity fuel Fuel tank content 12 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 P 168 Fuel reserve 2 5 2 6 qt TECHNICAL DATA FORK Fork part number 14 18 7D 11 Fork WP 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 472 mm 18 58 in Spring rate Weight of rider 75 85 kg 165 187 Ib 5 4 N mm 30 8 Ib in Air chamber length 110 20 mm 4 33 0 79 in Fork length 890 mm 35 04 in Fork oil P 167 SAE 5
39. when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately MAINTENANCE WORK ON CHASSIS AND ENGINE 125 Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children c Condition Engine is cold Stand the motorcycle on its side stand on a horizontal surface d 2 ME Check the coolant level in the compensating tank O A The coolant level must be within the range shown in the figure gt a Ifthe level of the cooling liquid does not meet specifications LI aa Correct the coolant level 1100283 10 Alternative 1 Coolant P 166 Alternative 2 Coolant mixed ready to use P 166 MAINTENANCE WORK ON CHASSIS AND ENGINE 126 Screw off the radiator cap O and check the coolant level in the radiator The radiator must be completely full Ifthe level of the cooling liquid does not meet specifications Correct the coolant level and find out the cause of the loss Alt
40. 10 For safety reasons the chain has no chain joint Always have the chain replaced in an authorized KTM workshop where the necessary chain rivet tool is available Check chain guides for tightness and wear MAINTENANCE WORK ON CHASSIS AND ENGINE 14 Checking chain wear Shift into neutral pull the lower chain section with the specified weight O Specification Weight of chain wear measurement 15 kg 33 Ib Measure the distance of 18 chain links in the lower chain section e Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest 272 mm 10 71 in chain section If the distance is greater than the specified measurement Have the chain changed o e Info When the chain is replaced the rear sprocket and engine sprocket O OVO Oy _ _ O OKO O should also be changed New chains wear out faster on old worn sprockets 123 16 17 18 For safety reasons the chain has no chain joint Always have the chain 400409 10 changed in an authorized KTM workshop where the necessary tool is available MAINTENANCE WORK ON CHASSIS AND ENGINE 15 Remove screws and Take off the chain guide Conditions Number of teeth lt 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and O Specification Remaining screw
41. 6 The chassis number is stamped on the steering head on the right Type label O is located on the upper right frame tube below the seat LOCATION OF SERIAL NUMBERS 17 The key number can be found on the KEYCODECARD e Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place The engine number is stamped on the left side of the engine under the engine sprocket 100211 10 LOCATION OF SERIAL NUMBERS ko The fork part number is stamped on the inner side of the fork stub 100214 10 Shock absorber part number can be viewed from the right side 1 100216 10 OPERATING ELEMENTS Clutch lever The clutch lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 100219 10 The hand break lever is fitted on the right side of the handlebar The hand brake lever operates the front brake 100220 10 OPERATING ELEMENTS The light switch is fitted on the left side of the handlebar Possible states Low beam on Light switch is turned downwards In this position the low beam and tail light are switched on High beam on Light switch is turned upwards In this position the high D beam and the tail light are switched on 100222 10 The light switch is fitted on the left side of the handlebar Possible
42. 6 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 95 Fully tighten screw Specification Screw fork stub M8 15 Nm 11 1 Ibf ft Removing rear wheel Jack up the motorcycle P 56 Press the brake caliper by hand on to the brake disc in order to press back the brake piston Remove nut Remove chain adjuster Holding the rear wheel withdraw the wheel spindle Push the rear wheel forwards as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking due to damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Take the rear wheel out of the swing arm e Info Do not operate the foot brake when the rear wheel is removed MAINTENANCE WORK ON CHASSIS AND ENGINE 96 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the footbrake until the pressure point is reached Checking the rear hub rubber dampers X P 97 Check parts for damage and wear Replace damaged or worn parts Remove the bushing Clean and grease the roll surfaces of the bushing and the shaft seal ring Long life greas
43. Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary MAINTENANCE WORK ON CHASSIS AND ENGINE 71 Lean the motorcycle on the side stand Shift gear to neutral Push the chain upward at a distance from the chain sliding guard and determine the chain tension O Info e I The upper chain section 8 must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Chain tension 5 mm 0 2 in Distance to chain sliding guard 30 mm 1 18 in If the chain tension does not meet specifications Adjust the chain tension P 71 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chai
44. Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu ti on between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Specification Maximum permissible overall weight 350 kg 772 Ib Maximum permissible front axle load 150 kg 331 Ib Maximum permissible rear axle load 200 kg 441 Ib RIDING INSTRUCTIONS Checks before putting into operation e Info Make sure that the motorcycle is in a perfect technical condition before use In the interests of riding safety make a habit of making a general check before you ride Check the engine oil level P 133 Check the engine for loss of oil Check the fuel level Bleed fork legs P 62 Specification all 1 000 km 621 4 mi Check the chain tension P 70 Clean the chain P 69 Check the tire condition P 98 Checking the tire air pressure P 100 Check the front brake brake fluid level P 78 Check the rear brake fluid level P 86 Check
45. M6 10 Nm 7 4 Ibf ft Loctite 243 Screw timing chain guide rail M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw generator cover M6 10 Nm 7 4 Ibf ft Screw in generator cover chain shaft M6 10 Nm 7 4 Ibf ft Loctite 243 through hole Screw ignition pulse generator M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw rocker arm shaft M6 12 Nm 8 9 Ibf ft Screw clutch cover M6 10 Nm 7 4 Ibf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 Ibf ft Loctite 2437 Screw clutch slave cylinder M6x35 10 Nm 7 4 Ibf ft TECHNICAL DATA ENGINE TIGHTENING TORQUES Screw engine housing M6 10 Nm 7 4 Ibf ft Screw shift drum locating M6 10 Nm 7 4 Ibf ft Loctite 243 Screw shift lever M6 10 Nm 7 4 Ibf ft Loctite 222 Screw timing chain tensioning rail M6 10 Nm 7 4 Ibf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 Ibf ft Loctite 243 Screw stator bracket M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw thermostat housing M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw valve cover M6 10 Nm 7 4 Ibf ft Screw water pump cover M6 10 Nm 7 4 Ibf ft Screw water pump wheel M6 10 Nm 7 4 Ibf ft Loctite 243 Screw cylinder M6 10 Nm 7 4 Ibf ft Loctite 243 Screw cylinder head M6 10 Nm 7 4 Ibf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 Ibf ft Loctite 243 Stud exhaust flange M8 10 Nm 7 4 Ibf ft
46. Map Select switch and holder upward off of the retaining bracket Pull the Map Select switch out of the holder Turn the adjusting wheel until the desired digit is next to marking Set the Map Select switch to Soft Set the adjusting wheel to position 1 Y Soft reduced homologated peak performance for better driveability Set the Map Select switch to Advanced Setthe adjusting wheel to position 2 Y Advanced homologated performance with extremely direct responsiveness E Set the Map Select switch to Standard Bv Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Y Standard homologated performance with balanced responsiveness Set the Map Select switch to poor fuel quality Set the adjusting wheel to position 0 Y 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 Mount the seat P 103 MAINTENANCE WORK ON CHASSIS AND ENGINE Removing headlight mask with headlight Switch off all power consuming components and switch off the engine Protect the fender against damage by covering it with a cloth Remove the screws on the left and right Tilt the headlight mask forward and lift it off Disconnect the connectors of flasher lights and hea
47. NCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever e Info I Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw O Checking correcting fluid level of hydraulic clutch e 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 MAINTENANCE WORK ON CHASSIS AND ENGINE 400192 10 Remove screws O Remove the cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in Ifthe fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 P 167 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws Move the handlebar to the straight ahead position Move the throttle grip backwards and forwards to ascertain the play in the gas Bowden cable Play in ga
48. NE 98 Check rubber dampers O 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 Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play hold the rear wheel tight and try to rotate the rear sprocket e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm x 0 2 in Ifthe play O is more than the specified value Change all rubber dampers in the rear hub Fit the rear wheel P 96 Warning Danger of accidents Uncontrollable handling behavior caused by a flat tire For your own safety have damaged tires changed immediately MAINTENANCE WORK ON CHASSIS AND ENGINE A A Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling behavior caused by non approved tires wheels Use only tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surf
49. OWNER S MANUAL 2008 690 ENDURO EU 690 ENDURO AUS UK ART NO 3211239en AS a PO N gt DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle You are now the owner of a state of the art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly We wish you great pleasure riding the vehicle Enter the serial numbers of your vehicle below Chassis number P 16 Dealer s stamp Engine number P 17 Key number P 17 The owner s manual corresponded to the latest state of this series at the time of printing However it is never possible to exclude small deviations arising from further development in design and construction All specifications are not binding KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options devi ations from illustrations and descriptions as well as printing and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of delivery DEAR KTM CUSTOMER 2 2008 by KTM Sportmotorcycle AG Mattighofen Austria All ri
50. RATING ELEMENTS 24 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey The seat can be released using strap O 100230 10 OPERATING ELEMENTS 35 The passenger footrests can be folded up and down Possible states e Passenger footrests folded up For operation without a passenger e Passenger footrests folded down For operation with a passenger The shift lever is mounted on the left side of the engine 100215 10 OPERATING ELEMENTS 36 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 100212 10 The footbrake pedal is located in front of the right footrest The footbrake pedal operates the rear brake 100232 10 OPERATING ELEMENTS The side stand is coupled with the safety electric starter system see the riding instruc tions Possible states e Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active e Side stand folded in This position is mandatory for all journeys The safety electric starter system is inactive ___GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Advice on first use A A A gt Danger Danger of accidents Danger from inadequate traffic experience Do not use the vehicle if you a
51. RK ON CHASSIS AND ENGINE 137 Check parts for damage and wear Replace damaged or worn parts Insert oil filter 8 and Oil the O rings of the oil filter cover Refit the oil filter cover and O Mount and tighten screws Specification Screw oil filter cover M5 6 Nm 4 4 Ibf ft 100204 10 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine MAINTENANCE WORK ON CHASSIS AND ENGINE 138 Remove the plug with the oil screen and O rings 100205 10 Remove the plug with the oil screen O and O rings Drain the remaining engine oil Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts 100206 10 Position oil screen with O rings Refit plug O with O ring and tighten it Specification Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft 100207 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 139 Position oil screen with O rings Refit plug with O
52. ace must be roughened in the first 200 kilometers 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Info The type condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces Check the front and rear tire for cuts penetrations and other damage If the tires exhibits cuts penetrations or other damage Change the tires MAINTENANCE WORK ON CHASSIS AND ENGINE Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth Minimum tread depth gt 2 mm gt 0 08 in If the minimum tread depth is insufficient Change the tires Checking tire air pressure e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove dust cap 100274 01 MAINTENANCE WORK ON CHASSIS AND ENGINE Check tire air pressure when tires are cold Tire air pressure offroad single rider front 1 5 bar 22 psi Rear 1 5 bar 22 psi Tire air pressure road solo front 1 8 bar 26 psi Rear 1 8 bar 26 psi Tire air pressure with passenger fully loaded front 2 0 bar 29 psi Rear 2 2 ba
53. briefly 2x generator circuit generator A 06 Fl warning lamp MIL flashes Input signal from throttle valve Check the throttle valve sen briefly 6x sensor too low high sor X 08 Fl warning lamp MIL flashes Input signal from throttle grip Check the throttle grip sen briefly 8x sensor too low high sor A 09 Fl warning lamp MIL flashes Input signal from pressure sen Check the pressure sen briefly 9x sor of induction manifold too sor of the induction mani low high fold A 12 Fl warning lamp MIL flashes 1x Input signal from coolant tem Check the temperature sen long 2x short perature sensor too low high sor coolant X 13 Fl warning lamp MIL flashes 1x Input signal from intake air Check the intake air temper long 3x short temperature sensor too low high ature sensor 14 Fl warning lamp MIL flashes 1x Input signal from ambient air Check the ambient air pres long 4x short pressure sensor too low high sure sensor 15 Fl warning lamp MIL flashes 1x Input signal from roll angle sen Check the roll angle sen long 5x short sor too low high sor 17 Fl warning lamp MIL flashes 1x Malfunction in lambda probe Check the lambda probe 4 long 7x short circuit 24 Fl warning lamp MIL flashes 2x Malfunction in voltage supply Check the EFI control unit long 4x short circuit of EFI control unit voltage supply A 25 Fl warning lamp MIL flashes 2x Malfunction in side stand Check the sid
54. dlight Place the headlight mask to one side MAINTENANCE WORK ON CHASSIS AND ENGINE 114 Connect the connectors of headlight and flasher lights Check lighting function Remove the cloth from the fender attach the headlight mask to points on the fender and swing it up to the steering head OE 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 115 Position brake hose guide O Mount and tighten screws O Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Changing the headlight bulb Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the glass will evaporate by the heat and be deposited on the reflector Remove the headlight mask with the headlight P 113 Pull off connector Take off rubber cap of the headlight bulb MAINTENANCE WORK ON CHASSIS AND ENGINE 116 Detach spring bar Remove headlight bulb O Insert a new headlight bulb into the headlight housing Headlight H4 P43t P 158 Fit the headlight bulb in the headlight using the spring bar Replace the rubber cap Attach the connector Refit the headlight mask with the headlight P 114 Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any
55. e P 170 Clean and grease the thread of the wheel spindle and nut O Long life grease P 170 Mount the rubber damper and rear sprocket carrier in the rear wheel 100269 10 Place the rear wheel in the swingarm and bring the brake disc on the brake caliper into contact MAINTENANCE WORK ON CHASSIS AND ENGINE 97 Push the rear wheel forward as far as possible and place the chain on the rear sprocket Mount the wheel spindle chain adjuster and nut Specification In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks O e Info Fit the chain left and right adjusters in similar positions 100270 10 Tighten nut O Specification Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Remove the motorcycle from the work stand P 56 Checking the rear hub rubber dampers 4 e Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They eventually wear out during operation If the rubber dampers are not changed in time the rear sprocket carrier and the rear hub will be damaged Remove the rear wheel P 95 MAINTENANCE WORK ON CHASSIS AND ENGI
56. e able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust play of the steering head bearing X P 66 Check the steering head bearing and change if necessary Remove the motorcycle from the work stand P 56 MAINTENANCE WORK ON CHASSIS AND ENGINE 66 Adjusting play of steering head bearing A Jack up the motorcycle P 56 Loosen screw Remove screw Loosen and retighten screw 6 Specification Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw O Specification MA Screw top triple clamp M8 17 Nm 12 5 Ibf ft Mount and tighten screw O Specification Screw steering stem M8 20 Nm Loctite 2437 14 8 Ibf ft Check play of steering head bearing X P 65 Remove the motorcycle from the work stand P 56 MAINTENANCE WORK ON CHASSIS AND ENGINE 67 Adjusting the handlebar angle A Loosen screw O Move the handlebar to the desired position and slightly tichten the screws Move the handlebar carefully in both directions as far as it will go Ifthe handlebar instruments touch the fuel tank Correct the handlebar angle e Info The distance between the handlebar support and the handlebar clamp mu
57. e stand long 5x short switch circuit switch X 26 Fl warning lamp MIL flashes 2x Malfunction in Hall sensor Check the Hall sensor throt long 6x short throttle valve control circuit tle valve control X FLASHING CODE 145 Fault Description Possible cause Action 27 Fl warning lamp MIL flashes 2x Malfunction in voltage supply Check the throttle valve con long 7x short circuit of throttle valve control trol unit voltage supply A unit 33 Fl warning lamp MIL flashes 3x Malfunction in injection valve Check the injection long 3x short circuit valve A 37 Fl warning lamp MIL flashes 3x Malfunction in ignition coil cir Check the ignition coil X long 7x short cuit 41 Fl warning lamp MIL flashes 4x Fault short circuit in fuel pump Check the fuel pump con long 1x short control circuit trol A 45 FI warning lamp MIL flashes 4x Malfunction or short circuit Check the lambda probe long 5x short after positive in lambda probe heating A heating circuit 54 Fl warning lamp MIL flashes 5x Fault short circuit in secondary Check the secondary air long 4x short air valve circuit valve A 55 Fl warning lamp MIL flashes 5x Malfunction in throttle valve Check the throttle valve con long 5x short control unit circuit internal trol unit A 58 Fl warning lamp MIL flashes 5x Malfunction in release of th
58. e tells you which component is affected by a fault Braking A A Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake Have the brake system checked in an authorized KTM workshop and do not ride any further RIDING INSTRUCTIONS 49 0 Warning Danger of accidents Brake system failure Ifthe foot brake pedal is not released the brake linings drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake T Warning Danger of accidents Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage Warning Danger of accidents Delayed brake action on salted roads Salt can be deposited on the brake discs To achieve the normal braking effect the brake discs must first be cleaned by brak ing To brake release the throttle and operate the front and rear brakes simultaneously On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear app
59. ebar clamp M8 20 Nm Loctite 243 14 8 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain dirt Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain P 69 Cleaning the chain A A HW 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 due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info The service life of the chain depends largely on its maintenance Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner P 169 MAINTENANCE WORK ON CHASSIS AND ENGINE 70 After drying apply chain spray Offroad chain spray P 170 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension Ifthe chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load
60. ect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault Engine has too little power Air filter very dirty Have the air filter changed TROUBLESHOOTING 142 Faults Engine has too little power Possible cause Fuel filter very dirty Action Have the fuel filter changed Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level P 124 Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant A P 126 Fill the cooling system X P 127 Buckled or damaged radiator hose Have the radiator hose changed Thermostat defective Have thermostat checked Fuse 5 blown Change the fuses of individual power consumers P 109 Defect in radiator fan system Have the radiator fan system checked Air in cooling system Fill the cooling system X P 127 FI warning lamp MIL lights flashes Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault Engine dies during the journey Lack of fuel Fill up with fuel P 51 Fuse 1 2 or 4 blown Change the fuses of individual power consumers P 109 Hig
61. eering head bearing pl Checking siei merei b lev n het ke dedo m ae ler de 97 teering ce caring pray adJUstlrg eios suum ash aad c Poa A peus Sb a E RE RR 66 Rear sprocket engine sprocket CHECKING u apu eae RR E Qs efe e Be Rates oA 65 checking for wear lt gt xxm eme gem A eR REUS RECS 73 Steering lock LL A KK KK KK RR leeren 24 Rear wheel Stopping gt os aes HHHH 49 fitting N ee ET E o pd 29 Storage son giu tee See Gains eus dada 150 FEMOVING gt zio od A a teneo e EE ada 95 T Riding ss AA NEST 45 A DB HH REH 45 Tachometer eee alee m RR REY Re 26 INDEX Technical data ChasSIS iii ech Maou ee ala ea da Ree RO MUS 157 159 Chassis tightening torques o ooooooo 163 165 Englhe 4i ese eerie racks Peas 152 153 Engine tightening torques kak kk RR RR KK 154 156 dod EXEC es E cones ee ye es Bod 160 Shock absorber Ak ak kk KK KK KIRI KI KIR eee eee 161 162 Tire air pressure checking br DD Os 100 Tire condition checking odes dad hla lr dul ak hed eee dees 98 Transport 4 245 c2 3l Ely diy Ss etd beige ted redde SER 9 Troubleshooting KK KK 141 143 Type label aac cig EE rk aa a daa a ERR 16 View of vehicle irontleit Anas a eodd a ee wey a ce na 12 rear right side iud oe por CEU RUN xD 14 3211239en 03 2008 Photo Mitterbauer
62. ernative 1 Coolant P 166 Alternative 2 A Coolant mixed ready to use P 166 Refit the radiator cap Draining coolant X Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Remove the engine guard P 132 MAINTENANCE WORK ON CHASSIS AND ENGINE 127 Stand the vehicle upright Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Fit screw with a new seal and tighten it Specification Plug drain hole of water pump M10x1 15 Nm 11 1 Ibf ft 600616 10 Install the engine guard P 132 Filling the cooling system 4 Warning Danger of poisoning Coo
63. etting the tlok curras ea ra bb od aya ned 29 INDEX 173 Setting resetting TRIP 1 display 30 Engine number 2 0063 46 do EUR VS ne 17 Setting resetting TRIP 2 display 31 Engine oil Speedidisplayi a vida A 28 E aul lt n nnn HE 133 Tachometer iex Ane ane eva heeded de U a a 26 da 2s dulce veia d orte t Mo so d d hee aia 134 Time coo 29 refilling a a it ad bdo 139 Conservation for winter operation 149 TOPPING UP iode xu a A td N E 140 Coolant Engine oil level dIalhnIng iu DY DD DD Sale eade 126 CHECKING Mactan are e adas dere ag E INA 133 Coolant level Environment sico 202 4 dus ea ew rat SO s 9 CHECKING 5 c ens tesa tienes REG RS 122 124 F SAE aad a E EE 1 E y Filler cap MO AS M Brine A O H ClOSITIB trate bos eade p ACIE sn 33 D OPENING ras sale aww DH DEAS 33 Display lt iki i 42 ran e ee xedar cn REE 27 Filling up Dust boots Fuel sik SAY ae Sheng d Ps eee 51 cleaning aside ely fa kan bn FA APs wd ds OS Mate dir do ca shes cae Cady i o abs A 63 Flasher bulb E Changing 3e Eya eae b eee a len 117 Electric starter button u KK KK KK 24 Flasherswitch 4 A lt jL akla Q W A k b lye eee 21 22 Emergency OFF switch o o ooo 23 Flashing code o o ooo coco oo 144 146 Engine Foot brake pedal AK KK KK KK R KK RR eee 36 A DD n ee 40 adjusting basic position
64. fort 20 clicks Standard 15 clicks Sport 10 clicks a full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Lean the motorcycle on the side stand MAINTENANCE WORK ON CHASSIS AND ENGINE 63 Remove bleeder screws briefly Y Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws e Info Carry out this action on both fork legs Jack up the motorcycle P 56 Loosen the fork protection P 64 Push dust boots of both fork legs downwards e Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray P 170 Press the dust boots back into their normal position MAINTENANCE WORK ON CHASSIS AND ENGINE 64 Remove excess oil Position the fork protection P 64 Remove the motorcycle from the work stand P 56 Loosening the fork protection Remove screws and take off clamp Remove
65. ge The OBD has detected an emission or safety critical error W Fuel level warning lamp lights up orange Fuel level has reached the reserve OPERATING ELEMENTS 21 Battery warning lamp lights up Voltage in electrical system too low When you switch on the ignition all display segments light up for a second as a function test GEE IBABA 700118 01 LEnGTth Following the display function test the wheel circumference LEnGth is shown for one sec ond e Info 2205 mm equals the circumference of the 21 front wheel with a series production tire The display then changes to the last selected mode 400404 01 OPERATING ELEMENTS 28 The speed O is displayed in kilometers per hour km h or miles per hour Mph CIDO cof J88 700114 01 e Info If you change the unit the ODO value is retained and converted accordingly Making the setting according to the country Condition The motorcycle is standing OPERATING ELEMENTS 700120 01 700115 01 from Mph to Km h Specification Switch on the ignition by turning the ignition key in the position Press the MODE button several times until the ODO display mode is active Keep the MODE button pressed until the display mode changes from Km h to Mph or Activation duration of MODE button 10s The time is shown in area O of the display e Info The time must be adju
66. ge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery becomes discharged from starting it must be recharged immediately If the battery rests for an extended time in a discharged state it becomes over discharged and sulfated which will result in its destruction The battery is maintenance free e the acid level does not have to be checked Switch off all power consuming components and switch off the engine Remove the battery A P 103 MAINTENANCE WORK ON CHASSIS AND ENGINE 107 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the bat tery and to test the generator With this device you cannot overcharge the battery e Info Never remove the lid O Charge the battery according to the instructions on the battery casing After charging switch off and disconnect the battery charger Specification The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Install the battery A P 104 100151 10 Changing the main fuse Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed ampe
67. ghts reserved Reproduction even in part is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 N Within the meaning of the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service 150 9001 REG NO 12 100 6061 KTM Sportmotorcycle AG 5230 Mattighofen Austria CONTENTS 3 MEANS OF REPRESENTATION M K kek n 7 Combination instrument Display 27 IMPORTANT NOTES uue eee keke keke kk 8 Combination instrument speed display j 28 VIEW OF VEHICLE 2 0 eee tette tt de dee oed aie 12 Setting kilometers or miles L EEEL EEL 28 View of vehicle front left Side kk 12 Combination instrument time sssesee 29 View of vehicle rear right side oocccccccooccccnnccooncnnncconcnnnn 14 Setting the clock caia Ein a 29 LOCATION OF SERIAL NUMBERS nenne 16 Combination instrument ODO display jlj 30 Chassis HW Del dla 0R hu 16 Combination instrument setting resetting TRIP 1 display 30 BEI EEDI CC at i ek de w eve W rik 16 Combination instrument setting resetting TRIP 2 display 31 Key NUMBER oral 17 Combination instrument TRIP F display 32 Engine Number eit cosa aid 17 Combination instrument coolant temperature indicator
68. h oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level P 133 Engine oil too thin low viscosity Change engine oil and oil filter clean oil screens X P 133 TROUBLESHOOTING 143 Faults Possible cause Action Headlight and parking light not functioning Fuse 7 blown Change the fuses of individual power consumers P 109 Flasher light brake light and horn not Fuse 6 blown Change the fuses of individual power functioning consumers P 109 Time is not correctly displayed Fuse 2 blown Change the fuses of individual power consumers P 109 Set the clock P 29 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery 4 P 105 Battery is not charged by generator Check charging voltage Combination instrument shows nothing in the display Fuse 1 blown Change the fuses of individual power consumers P 109 Speedometer in combination instrument not functioning Speedometer cable harness damaged or plug oxidized Have the cable harness and plug checked FLASHING CODE 144 Fault Description Possible cause Action 02 FI warning lamp MIL flashes Malfunction in ignition pulse Check the ignition pulse
69. he compensating tank O Check antifreeze of coolant 25 45 C 13 49 F Ifthe antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant Check the coolant level in the compensating tank The coolant level must be within the range shown in the figure Ifthe level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant P 166 Alternative 2 Coolant mixed ready to use P 166 Mount the cap of the compensating tank MAINTENANCE WORK ON CHASSIS AND ENGINE 20 10028410 Checking the coolant level Warning Screw off the radiator cap Check antifreeze of coolant 25 45 C 13 49 F If the antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant Check the coolant level in the radiator The radiator must be completely full If the level of the cooling liquid does not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant P 166 Alternative 2 Coolant mixed ready to use P 166 Refit the radiator cap Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components
70. he distance between refuelling stops After reaching 999 9 the tripmaster begins again at 0 0 Switch on the ignition by turning the ignition key in the position Press the MODE button several times until the TRIP 2 display mode is active Keep the SET button pressed The TRIP 2 display is at 0 0 2400 e 587 700122 01 OPERATING ELEMENTS 32 When the fuel level reaches the reserve mark the display automatically changes to TRIP F and begins to count from 0 0 regardless of which display mode was previously active e Info Parallel to the TRIP F display the fuel warning light begins to light up 700123 01 The temperature indicator in the display consists of 12 bars The more bars that light up the hotter the coolant When the top bar lights up all bars begin to flash simultaneously and the temperature warning lamp begins to light up Possible states e Engine cold up to four bars light up e Engine at normal operating temperature from five to eleven bars light up e Engine hot all twelve bars flash OPERATING ELEMENTS aa Lift the cover of the filler cap O and insert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap e Info The filler cap has a tank air vent system Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover OPE
71. he throttle Loading the vehicle A A Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warning Danger of accidents Risk of breakage of suitcase system f you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload ___GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION A A A A Warning Danger of accidents Poor visibility for other road users due to slipped baggage Ifthe tail light is covered you are less visible to following traffic especially in the dark Check the way your baggage is fixed regularly Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload Adapt your speed according to your payload Warning
72. hecking chain dirt sees 69 Checking spoke tenSiOn cccccccecesccceeceeeeeeeeeeeeeeeeeanees 101 CONTENTS 5 Removing the Seat occcooccccoccncccnnnconnnccnonnnononononnnonnnnnnnnns 102 Changing engine oil and oil filter cleaning oil Mounting the seat hk kk kk eke 103 Screens c so bote s doe nah kr nad a kn bek 133 Removing the battery et AA di a YD DE ols 103 Draining engine oil Wrote e Heve e e N ARE 134 Installing the battery V 104 Removing the oil filter h e 135 Recharging the battery A e eN el Le e PO a 105 Mounting oil filter A aye Xu EE eU Tum e Pa eR Ee bri A ETAT EN EAVMRRE S 137 Changing the main fuse hkhbAG 4 444x eee 107 Cleaning oll screens Use 137 Changing fuses of individual power consumers 109 Filling up with engine oil V 139 Adjusting the engine characteristic sussesssse 111 TOPPING up engine oil cooocccccccncnccnncononononononacnnnnncnnnnos 140 Removing headlight mask with headlight 113 TROUBLESHOOTING Rat 141 Refitting the headlight mask with the headlight 114 FLASHING CODE cra Dal 144 Changing the headlight DulD E 11 5 CLEANING eset d eot siete ee ee stew cates 147 Changing the parking light bulb occccocccccccncnoccnconcnnnos 116 Gleanings motorcycles 2 id e e satt eis 147 Changing the flasher bulb ke 117 CONSERVATION FOR WINTER OPERATION
73. icator lamp N O lights up Press the electric starter button e Info Do not press the electric starter button until the combination instrument func tion test is finished Do not open the throttle when starting If you open the throttle when starting the engine management injects no fuel and the engine cannot start Press the starter for a maximum of 5 seconds Wait for at least 5 seconds until trying again This motorcycle is equipped with a safety electric starter system The engine can be started only if the gearbox is in neutral or the clutch lever is pulled If you shift into gear when the side stand is folded out and then release the clutch lever the engine stalls Take the weight off the side stand and swing it back up with your foot as far as it will go RIDING INSTRUCTIONS Starting up Pull the clutch lever engage lst gear release the clutch lever slowly and simultaneously open the throttle carefully Shifting riding Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions Warning Danger of accidents f you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can block Warning Danger of accidents Malfunctions caused by incorrect ignition key positio
74. ied coolant temperature is therefore permissible without danger of function prob lems 125 C 257 F 600614 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 122 The coolant is cooled by the air stream and a radiator fan which is controlled by a ther moswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 400407 10 Checking the antifreeze and coolant level Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children TE Z A gt al Y 100283 10 MAINTENANCE WORK ON CHASSIS AND ENGINE Condition Engine is cold Stand the motorcycle on its side stand on a horizontal surface Remove the cap of t
75. igned 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 MAINTENANCE WORK ON CHASSIS AND ENGINE Stand the vehicle upright tion it off if necessary Remove screw cover with membrane Press the brake caliper by hand on to the brake disc in order to press back the brake piston Ensure that brake fluid does not overflow from the brake fluid reservoir and suc e Info caliper against the spokes Make sure when pushing back the brake piston that you do not press the brake linings support are seated correctly 400419 10 Remove split pin remove bolt O toward the left by striking it and remove the brake Clean brake caliper and brake caliper support Check parts for damage and wear Replace damaged or worn parts Check that leaf spring in the brake caliper and sliding plate O in the brake caliper MAINTENANCE WORK ON CHASSIS AND ENGINE 92 Insert the brake pads insert the bolt and mount the split pin Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Adjust the brake fluid level to the MAX mark Brake fluid DOT 4 DOT 5 1 P 166 Refit screw with membrane e Info Clean up overflowed or spilt brake fluid immediately with water Jack up the motorcyc
76. ion on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not des
77. ise to reduce the light range If you have a payload you may have to correct the headlight range Remove the seat P 102 Remove screws Remove filter box top MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter X 100286 10 100287 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 Remove air filter Check parts for damage and wear Change damaged or worn parts Change the air filter if it is dirty or wet Clean the air filter box Mount air filter O e Info The air filter must be in contact with the air filter box along the entire sealing surface Attach filter box top at the front of the air filter box and swing it down MAINTENANCE WORK ON CHASSIS AND ENGINE 121 Mount and tighten screws ES Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Mount the seat P 103 100285 11 The water pump in the engine forces the coolant to flow The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap Heat expansion causes excess coolant to flow into the compensating tank 6 If the temperature falls the excess coolant is sucked back into the cooling system The specif
78. ke fluid DOT 4 DOT 5 1 P 166 Check parts for damage and wear Replace damaged or worn parts 100254 10 _ pogition the cover with the membrane Mount and tighten screws e Info Clean up overflowed or spilt brake fluid immediately with water Brake linings The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties The type names of brake pads are entered in the homologation documents Info Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid MAINTENANCE WORK ON CHASSIS AND ENGINE 81 Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Note Danger of accidents Reduced braking due to damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings for minimum thickness O
79. l P 133 TROUBLESHOOTING 141 Faults Engine does not turn when the electric starter button is pressed Possible cause Operating error Action Carry out the instructions for starting P 43 Battery discharged Recharge the battery X P 105 Check the cause of discharging Fuse 1 2 3 or 4 blown Change the fuses of individual power consumers P 109 Main fuse burned out Change the main fuse P 107 Ignition steering lock or emergency OFF switch defective Have ignition steering lock or emergency OFF switch checked Defect in safety start system Have the safety start system checked Engine turns only if the clutch lever is drawn The vehicle is in gear Shift gear to neutral The vehicle is in gear and the side stand is folded out Shift gear to neutral Defect in safety start system Have the safety start system checked Engine turns although a gear is engaged Defect in safety start system Have the safety start system checked Engine turns but does not start Operating error Carry out the instructions for starting P 43 Fuse 4 blown Change the fuses of individual power consumers P 109 Coupling of fuel hose connection not con nected Reconnect coupling of fuel hose connec tion Socket connector of cable harness oxidized Clean socket connector and treat it with contact spray Def
80. l unit Fuse 4 10A fuel pump Fuse 5 10A radiator fan Fuse 6 10A horn brake light flasher light alarm system optional Fuse 7 15A high beam low beam parking light tail light license plate lamp Fuse 8 10A for supplementary equipment accessories connected with ignition switch Fuse 9 10A for supplementary equipment standard accessories Fuse 10 not used Fuse SPARE 10A 15A spare fuses Check parts for damage and wear Replace damaged or worn parts e Info A defective fuse is shown by a burned out fuse wire MAINTENANCE WORK ON CHASSIS AND ENGINE 111 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 P 158 Fuse 75011088015 P 158 e Info I If the new fuse burns out contact an authorized KTM workshop e Tip l Replace the spare fuse in the fuse box so that it will be available if needed Check the functioning of the power consumer Close the fuse box cover Mount the seat P 103 Adjusting the engine characteristic Switch off the ignition by turning the ignition key in the position i Remove the seat P 102 MAINTENANCE WORK ON CHASSIS AND ENGINE 112 Pull the
81. lants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Stand the motorcycle on its side stand on a horizontal surface Remove radiator cap O BEER 600618 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 100283 11 Refill the coolant Alternative 1 Coolant P 166 Alternative 2 Coolant mixed ready to use P 166 Fill the radiator completely with coolant Mount radiator cap O Remove the cap from compensating tank and add coolant to the level shown in the figure Mount the cap of the compensating tank Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and 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 MAINTENA
82. le P 56 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screw O Loosen screw Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged Remove the spacing sleeves MAINTENANCE WORK ON CHASSIS AND ENGINE 94 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check parts for damage and wear Replace damaged or worn parts Clean and grease shaft seal rings and bearing surface of the spacing sleeves Long life grease P 170 Fit the spacing sleeves Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw O Specification Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc oS 4 Remove the motorcycle from the work stand P 56 Pull the front wheel brake and push down hard on the fork several times to align the fork legs 10026
83. le remember that others may feel disturbed by excessive noise Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop You receive a delivery certificate and the service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the operating elements adjust the basic position of clutch lever P 129 Adjust the free travel of the handbrake lever P 77 Adjust the basic position of the foot brake pedal X P 85 Get used to handling the vehicle on a car park before making a longer trip Try also to ride as slowly as possible and in a standing posi tion to get a better feeling for the vehicle Do not make any offroad trips that over stress your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not make any changes to the vehicle and use only KTM approved parts e Info Parts from other manufacturers can reduce the operational safety of the vehicle Run the engine in ___GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Specification Maximum engine speed During the first 1 000 km 621 4 mi 6 000 rpm After the first 1 000 km 621 4 mi 7 800 rpm Avoid fully opening t
84. luid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further MAINTENANCE WORK ON CHASSIS AND ENGINE 79 Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid It is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position MAINTENANCE WORK ON CHASSIS AND ENGINE a0 Remove screws O Remove cover with membrane O Add brake fluid to level OQ Specification Measurement of 5 mm 0 2 in Bra
85. n Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury The passenger must be capable of sitting correctly on the passenger seat The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests Note the regulations governing the minimum age of passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible RIDING INSTRUCTIONS A A A A Note Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured Warning Danger of accidents Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surface must be roughened in the first 200 kilometers 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consist
86. n tension and adjust if necessary MAINTENANCE WORK ON CHASSIS AND ENGINE 12 Lean the motorcycle on the side stand Shift gear to neutral Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws left and right Specification Chain tension 5 mm 0 2 in Turn the adjusting screws left and right so that the markings on the left and right chain adjusters O are in the same position relative to the reference marks O The rear wheel is then correctly aligned e Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Tighten nuts Make sure that the chain adjusters O are fitted correctly on the adjusting screws Tighten nut O Specification Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters can be turned by 180 MAINTENANCE WORK ON CHASSIS AND ENGINE 73 Checking rear sprocket engine sprocket for wear Check rear sprocket engine sprocket for wear Ifthe rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket e Info The engine sprocket rear sprocket and chain should always be replaced together 100132
87. nd second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 5 bars of the temperature indicator light up 100212 10 When you reach maximum speed after fully opening the throttle turn back the throttle to about of its range the speed hardly drops but the fuel consumption falls consid erably Open the throttle only as far as the road and weather conditions permit Particularly in bends do not shift and open the throttle only very cautiously To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again RIDING INSTRUCTIONS 48 For example if the engine stalls at a junction just pull the clutch and press the electric starter button You do not need to shift into neutral Switch off the engine if you expect to be standing for a long time Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch Ifthe Fl warning lamp MIL starts to light up during the journey stop immediately If you shift to neutral the Fl warning lamp MIL begins to flash e Info From the flash rhythm you can deduce a two digit number the so called flash code The flash cod
88. nd turn it clockwise as far as it will go Flasher light BA15s P 158 Mount the orange cap Position the diffuser Insert the screw and turn it first counterclockwise until you feel it click into the thread Tighten the screw Check the flasher function Checking headlamp setting Ona light colored wall with a horizontal area in front of it make a mark as high as the O center of the low beam headlight gt Make another mark at a distance of under the first mark ern Specification Distance 5 cm 2 in Stand the motorcycle at a distance of in front of the wall and switch on the low beam Specification ae Distance 5m 16 ft Check the headlamp setting The boundary between light and dark must be exactly on the lower mark for a motor cycle with driver If the boundary between light and dark does not meet specifications Adjust the headlight range P 119 MAINTENANCE WORK ON CHASSIS AND ENGINE 119 100285 10 Check the headlamp setting P 118 Use a screwdriver see illustration to adjust the headlight range Specification The boundary between light and dark must be exactly on the lower mark for a motor cycle with a rider mark is applied under Checking headlight adjustment e Info Turn clockwise to increase the light range turn counterclockw
89. of the foot brake pedal X P 85 Adjusting basic position of foot brake pedal A Warning Danger of accidents Brake system failure If there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications MAINTENANCE WORK ON CHASSIS AND ENGINE 86 Remove screw connection on foot brake cylinder O To adjust the basic position of the foot brake pedal as needed loosen nut and turn screw accordingly e 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 O so that the foot brake pedal has the necessary free travel Hold screws in place and tighten the nuts Specification Nut foot brake cylinder screw M6 10 Nm 7 4 Ibf ft Check the free play of the foot brake lever P 85 Tighten nut O 100257 10 Checking rear brake fluid level Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid
90. on In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed DIS OPERATING ELEMENTS 25 The combination instrument is attached in fromt of the handlebar The combination instrument is divided into 4 function areas Function buttons Tachometer Indicator lights O Display 700116 01 Press the MODE button to change the display mode Possible display modes are total distance covered ODO tripmaster 1 TRIP 1 and tripmas ter 2 TRIP 2 Press the SET button to reset tripmaster 1 TRIP 1 and tripmaster 2 TRIP 2 to 0 0 Button has no function 90 00117 01 OPERATING ELEMENTS 26 The tachometer O displays the engine speed in revolutions per minute The red marking shows the excess engine speed range The indicator lamps provide additional information on the operating state of the motorcycle Possible states Flashing indicator flashes green in flash rhythm Flasher light is switched on Idling speed indicator lamp lights up green Transmission is in neutral ED High beam indicator lamp lights up blue High beam is switched on Temperature warning lamp lights up red Coolant has reached a critical value mark Display switches to TRIP F Fl warning lamp MIL lights flashes oran
91. on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances Switch off the engine and remove the ignition key Use straps or other suitable devices to secure the motorcycle against accidents or falling over Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest However it is a potential problem for the environment and can lead to conflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of others IMPORTANT NOTES o Pay attention to the specified notes and warnings e Info Various notes and warning labels are attached to the vehicle Do not remove any notes or warning labels If they are missing you or others may not recognize dangers and may therefore be injured Danger Danger that leads immediately and certainly to severe and permanent injury or death Warning Danger that will probably lead to severe and permanent injury or death Caution Danger that could possibly lead to slight injuries Note Danger of serious damage to machine or material Warning Risk
92. r 32 psi If the tire pressure does not meet specifications Correct tire pressure Mount dust cap Checking spoke tension Warning Danger of accidents Unstable riding behavior due to loose spokes If you ride with loose spokes the spokes can break Have the spoke tension corrected in an authorized KTM workshop Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle MAINTENANCE WORK ON CHASSIS AND ENGINE 102 To check spoke tension tap each spoke with a screwdriver Specification You should hear a high note Spoke nipple front wheel M5 4 Nm 3 Ibf ft Spoke nipple rear wheel M5 4 Nm 3 Ibf ft e Info If you hear different tone frequencies from different spokes this is an indication of different spoke tensions Pull on strap and raise the rear of the seat at the same time Pull back the seat and lift it off MAINTENANCE WORK ON CHASSIS AND ENGINE 103 Hook slot of the seat onto screw press the rear downward and at the same time push it forward Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click Finally check that the seat is correctly mounted
93. rage Never by pass or repair fuses MAINTENANCE WORK ON CHASSIS AND ENGINE 108 e Info The main fuse protects all power consuming components of the vehicle It is located in the housing of the electric starter relay next to the battery Switch off all power consuming components and switch off the engine Remove the seat P 102 Remove protection covers v Remove a defective main fuse with a needle nose plier Check parts for damage and wear Replace damaged or worn parts e Info A reserve fuse is located in the starter relay Fit anew main fuse Fuse 58011109130 P 158 600605 10 600605 10 Info If the new fuse burns out contact an authorized KTM workshop Check the functioning of the electrical equipment MAINTENANCE WORK ON CHASSIS AND ENGINE Attach the protection covers Mount the seat P 103 Set the clock P 29 e Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consuming components and switch off the engine Remove the seat P 102 Open the fuse box cover A MAINTENANCE WORK ON CHASSIS AND ENGINE Remove defective fuse Specification Fuse 1 10A ignition combination instrument alarm system optional Fuse 2 10A clock ignition EFI control unit Fuse 3 10A throttle valve contro
94. rake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Stand the vehicle upright Remove screw cover with membrane Top up the brake fluid to MAX level Brake fluid DOT 4 DOT 5 1 P 166 Check parts for damage and wear Replace damaged or worn parts Refit screw with membrane e Info Clean up overflowed or spilt brake fluid immediately with water 223 100259 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 89 Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Note Danger of accidents Reduced braking due to damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings for minimum thickness O Minimum thickness Q gt 1 mm gt 0 04 in If the minimum thickness is less than specified Change the rear brake linings A P 89 Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop MAINTENANCE WORK ON CHASSIS AND ENGINE A A gt Warning Skin irritations Brake fluid can cause skin irritat
95. re inexperienced or if you have consumed alcohol or drugs Warning Risk of injury Risk of injury by missing inadequate protective clothing Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the motorcycle Always wear protective clothing which must be in perfect condition and meet legal requirements Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling behavior caused by non approved tires wheels Use only tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surface must be roughened in the first 200 kilometers 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Warning Danger of accidents Brake system failure Ifthe foot brake pedal is not released the brake linings drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake ___GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 39 e Info When using your vehic
96. ropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way you have to brake far less and the brakes do not overheat Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key RIDING INSTRUCTIONS 50 Warning Danger of burns Some vehicle components get very hot when the machine is driven Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Brake the motorcycle
97. rot Check the throttle valve con long 8x short tle stepper in EPT mode trol unit A Check the EFI control unit A 60 Fl warning lamp MIL flashes 6x Malfunction in throttle stepper Check the throttle stepper long circuit motor 4 68 Fl warning lamp MIL flashes 6x Connection of pressure sensor Check the connection of long 8x short of induction manifold leaky the pressure sensor of the induction manifold X 90 Fl warning lamp MIL flashes 9x Throttle valve position not plau Check the throttle valve long sible position amp FLASHING CODE 146 Fault Description Possible cause Action 91 Fl warning lamp MIL flashes 9x Malfunction in CAN bus com Check CAN bus communica long 1x short munication tion A 92 Fl warning lamp MIL flashes 9x long 2x short Malfunction in voltage supply circuit of throttle valve control unit internal Check the throttle valve con trol unit A CLEANING 147 Cleaning motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment Never clean the vehicle with high pressure cleaning equipment or a strong water jet The excessive pressure can penetrate electrical components connects Bowden cables and bearings etc and can damage or destroy these parts Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease
98. rried out by an authorized KTM workshop as additional order Carry out a complete fork service K100A J1A J2A Carry out a complete shock absorber service X Clean and grease steering head bearing and sealing elements X Treat electric contacts with contact spray Clean the battery terminals and treat them with contact grease Change coolant X K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years MAINTENANCE WORK ON CHASSIS AND ENGINE 56 Jacking up the motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Jack up the motorcycle on the underride guard underneath the engine The wheels must no longer touch the ground Secure the motorcycle against falling over 100241 01 Removing the motorcycle from the work stand Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Remove the motorcycle from the work stand and rest it on its side stand Remove the work stand MAINTENANCE WORK ON CHASSIS AND ENGINE 57 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload e Info To help you adapt the vehicle we have summarized our findings in Table You can find the
99. s chassis M6 10 Nm 7 4 Ibf ft Conditions Number of teeth gt 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and O Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Warning Danger of accidents Reduced braking due to worn brake discs Worn brake discs should be replaced immediately in an authorized KTM workshop MAINTENANCE WORK ON CHASSIS AND ENGINE 16 400406 10 Checking free play of hand brake lever Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement O e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Wear limit of brake discs front 4 5 mm 0 177 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the brake disc 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 in the brake system The front brake can fail due to overheating Adjust free travel on hand brake lever according to specifications MAINTENANCE WORK ON CHASSIS AND ENGINE 0 100252 10 Push the hand brake to the handlebar and check free play O Free play of hand brake lever 2 3mm 20 12 in Ifthe
100. s Bowden cable 3 5 mm 0 12 0 2 in Ifthe gas Bowden cable play does not meet specifications Adjust the play in the gas Bowden cable X P 131 MAINTENANCE WORK ON CHASSIS AND ENGINE 131 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change Ifthe idle speed changes Adjust the play in the gas Bowden cable X P 131 Adjusting play in gas Bowden cable 4 Move the handlebar to the straight ahead position Loosen the lock nut O Adjust the play in the gas Bowden cable by turning the adjusting screw Specification Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten the lock nut 100280 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 132 Stand the motorcycle on its side stand on a horizontal surface Remove screws on the left and right Pull the engine guard forward out of the holders and set it down Slide the engine guard into holders at the rear Position the engine guard Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft
101. s of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of accidents After a fall check the vehicle After a fall check the vehicle as usual before putting it into operation 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 RIDING INSTRUCTIONS 41 Note Engine failure Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to cool down and check the coolant level in the radiator and top up if necessary If you continue with the coolant temperature warning lamp alight you may have engine failure Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle e Info For the positions of the 6 forward gears see the illustration The neutral or idle position is between the first a
102. scs P 75 Check the front brake brake fluid level P 78 Check the rear brake fluid level P 86 Change brake fluid X Check brake lines for damage and leakage Check the free play of the foot brake lever P 85 Check braking Check screws and guide bolts of brake system for tightness X Chassis Check shock absorber and fork for leakage and functioning A Clean dust boots of fork legs 4 Bleed fork legs P 62 Check swingarm bearing 4 Check play of steering head bearing A P 65 Check all screws to see if they are tight Grease Pro Lever deflector X Wheels Check the spoke tension P 101 Check rim run out X Check the tire condition P 98 Checking the tire air pressure P 100 GREASING AND SERVICE TABLE Wheels Check the chain wear P 74 K10N K50A K100A J1A Check rear sprocket engine sprocket for tightness Check rear sprocket engine sprocket for wear P 73 Check the chain tension P 70 Clean the chain P 69 Check wheel bearing for play A Checking the rear hub rubber dampers A P 97 K10N after 1 000 km 621 4 mi K50A every 5 000 km 3 107 mi after every race K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years Important maintenance work to be ca
103. ssis can lead to damage and breakage of components Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached Pay careful attention to the prescribed running in period inspection and maintenance intervals If you observe these exactly you will ensure a much longer service life for your motorcycle The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer s service record since otherwise no warranty claims will be recognized No warranty claims can be considered for damage resulting from manipulations and or alterations to the vehicle You should use the fuels oils and greases according to specifications as listed in the owner s manual IMPORTANT NOTES ko For your own safety use only spare parts and accessories approved by KTM and have these mounted only in an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle
104. st be the same at the front and rear Fully tighten screw O Specification Screw handlebar clamp M8 20 Nm Loctite 243 14 8 Ibf ft Handlebar position On the upper triple clamp there are 2 holes at a distance to each other Distance between holes 15 mm 0 59 in The holes on the handlebar support are placed at a distance O from the center Distance 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 MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar position 4 400271 10 Remove the four screws Remove the handlebar clamp Remove the handlebar and lay it to one side e Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove the two screws Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws Specification Screw handlebar support M10 40 Nm 29 5 Ibf ft e Info Position the left and right handlebar supports evenly Position the handlebar e Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Fit and evenly tighten the four screws O Specification Screw handl
105. states z Low beam on Light switch is turned downwards In this position the low beam and tail light are switched on High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on OPERATING ELEMENTS Headlight flasher switch The headlight flasher switch is fitted on the left side of the handlebar Possible states e Headlight flasher switch in neutral position e Headlight flasher switch pressed In this position the headlight flasher high beam is actuated 500020 11 Flasher switch The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use Flasher light right on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use To switch off the flasher light press the flasher switch towards the switch case 500021 10 OPERATING ELEMENTS 22 The flasher switch O is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use Flasher light right on Flasher switch pressed to the right The flasher switch returns automatically to
106. sted after the battery is disconnected or the fuse is changed Condition The motorcycle is standing OPERATING ELEMENTS Switch on the ignition by turning the ignition key in the position O Press the MODE button several times until the ODO display mode is active Keep the MODE button and the SET button pressed simultaneously Y The time begins to flash 7 gg Press the MODE button to adjust the hour c JUH gg 3 Press the SET button to adjust the minute Keep the MODE button and the SET button pressed simultaneously 700115 10 Y The time is set p In ODO mode the total distance covered is shown in kilometers or miles e Info This value remains intact even if the battery is disconnected and or the fuse blows 2305 88 J88 700120 01 Info The tripmaster TRIP 1 operates constantly and counts up to 999 9 You can use the tripmaster to measure trips or the distance between refuelling stops After reaching 999 9 the tripmaster begins again at 0 0 OPERATING ELEMENTS 31 Switch on the ignition by turning the ignition key in the position Press the MODE button several times until the TRIP 1 display mode is active Keep the SET button pressed Y The TRIP 1 display is at 0 0 2308 1 5838 700121 01 Info The tripmaster TRIP 2 operates constantly and counts up to 999 9 You can use the tripmaster to measure trips or t
107. the fork type Specification Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Compression damping of shock absorber The shock absorber can regulate compression damping in low and high speed range separately Dual Compression Control The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle The low and high speed technology works non specifically Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself e Info The low speed setting can be seen during the slow to normal compression of the shock absorber MAINTENANCE WORK ON CHASSIS AND ENGINE a0 Turn the adjusting screw clockwise with a screwdriver until it stops e Info Do not loosen nut Turn back counterclockwise the number of clicks corresponding to the shock absorber type Specification Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise
108. ting rebound damping TOR tee 58 Checking the front brake liningS sseeeeeeeseeeeeeeeeeeeees 81 Compression damping of shock absorber Wan PME ET 92 Changing the front brake linings A ec CE 8l Sling te lew speed compresion damping ofthe stock Checking ee play of foot rale eis ss Adjusting high speed compression damping of the shock Adjusting basic position of foot brake pedal Mins 85 Sbsorbar da es IN A e 60 Checking rear brake fluid level EEEEE E 86 Adjusting rebound damping of the shock absorber 62 Topping up brake fluid of rear brake amp 87 Bleeding fork ees A net 62 Checking the rear brake linings E 89 Cleaning dust boots of fork legs ocooonncncnocncnonacincconnnonnnoss 63 Changing rear brake linings 8 89 Loosening the fork protection kk 64 Removing front wheel 8 uu eee 92 Positioning the fork protection W L Ez 64 Fitting front wheel A icono conocia 94 Checking play of steering head bearing Aoi 65 Removing rear wheel MM 95 Adjusting play of steering head bearing amp 66 Fitting rear wheel VM ssssssssssssee 96 Adjusting the handlebar angle 8 67 Checking the rear hub rubber dampers ccoo 97 Handlebar position Lia a ects ase eee ken 67 Tire condition Checking coconcccnocnccononcconnnnonnnonononcnnenenonons 98 Adjusting handlebar position VM ocn 68 Checking tire air pressure L LE kk 100 C
109. ting screws for tightness Replace spark plug Check engine bolts accessible from outside for tightness Fuel injection Check connection boots for cracks and leakage V Read out the error memory with a KTM diagnostic tool A Check fuel hoses SLS hoses and vent hoses for damage correct fit ting and leaks X Clean check and grease the O ring of the fuel hose connection A Check the cable harness of the throttle valve body for damage and cor rect positioning 8 Attachments Check the cooling system for leakage Check the antifreeze and coolant level P 122 Check the functioning of the radiator fan 4 Check the exhaust system for leaks and correct fitting and check that the exhaust holders are tight A Check Bowden cables for damage smooth operation routing without sharp bends and setting Check correct the fluid level of the hydraulic clutch P 129 Check air filter and change if necessary Clean the air filter box X Check cables for damage and routing without sharp bends 4 Check the headlamp setting P 118 GREASING AND SERVICE TABLE 54 Attachments Check the functioning of the electrical equipment K10N K50A K100A J1A J2A Check screws and nuts for tightness Brakes Check the front brake linings P 81 Check the rear brake linings P 89 Check the brake di
110. to reduce suspension damping 100245 10 Adjusting high speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself MAINTENANCE WORK ON CHASSIS AND ENGINE 61 e Info The high speed setting can be seen during the fast compression of the shock absorber Turn the adjusting screw clockwise with an open ended spanner until it stops e Info Do not loosen nut 6 Turn back counterclockwise the number of turns corresponding to the shock absorber type Specification Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn full payload 1 turn e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 5 100246 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 62 Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself Turn the adjusting screw clockwise until it stops Turn back counterclockwise the number of clicks corresponding to the shock absorber type Specification Rebound damping Com
111. xana n kak ke a en 169 Checking engine oil level 133 CONTENTS MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following 4 x 4 Q7 Indicates an expected reaction e g of a work step or a function Indicates an unexpected reaction e g of a work step or a function All work marked with this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained in the following Eigenname Name Marke Indicates a proprietary name Identifies a protected name Identifies a brand in merchandise traffic IMPORTANT NOTES KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation dirt roads but not for use on race courses e Info The motorcycle is authorized for public road traffic in the homologous version only A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner s manual are properly carried out Poor adjustment and tuning of the engine and cha

Kenmore 596.58642 Refrigerator User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents