KTM 690 SUPERMOTO, 690 SUPERMOTO R User Manual

OWNER'S MANUAL 2008

690bSUPERMOTO

690bSUPERMOTObR

ART. NO. 3211244en

DEAR KTM CUSTOMER 1

'($5.70 &86720(5

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/type label ( P. 16) Dealer's stamp

Engine number ( P. 17)

Key number ( P. 16)

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 prudction of a particular model without prior notice. KTM accepts no liability for delivery options, devi­ations 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

© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that
lead to the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 3

&217(176

MEANS OF REPRESENTATION ............................................... 6

IMPORTANT NOTES ............................................................... 7

VIEW OF VEHICLE................................................................ 12

View of vehicle, front left side............................................ 12

View of vehicle, rear right side ........................................... 14

LOCATION OF SERIAL NUMBERS ......................................... 16

Chassis number/type label................................................. 16

Key number ..................................................................... 16

Engine number................................................................. 17

Fork part number.............................................................. 17

Shock absorber part number.............................................. 18

OPERATING ELEMENTS ....................................................... 19

Clutch lever ..................................................................... 19

Hand brake lever .............................................................. 20

Light switch ..................................................................... 20

Headlight flasher switch.................................................... 21

Flasher switch .................................................................. 21

Horn ............................................................................... 22

Ignition/steering lock ........................................................ 22

Emergency OFF switch...................................................... 23

Electric starter button ....................................................... 23

Combination instrument .................................................... 24

Combination instrument - function buttons ......................... 24

Combination instrument - tachometer................................. 25

Combination instrument - control lamps ............................. 25

Combination instrument - Display ...................................... 26

Combination instrument - speed display ............................. 27

Setting kilometers or miles ................................................ 27

Combination instrument - time .......................................... 28

Setting the clock .............................................................. 28

Combination instrument -bODO display ............................... 29

Combination instrument - setting/resettingbTRIPb1 display .... 29

Combination instrument - setting/resettingbTRIPb2 display .... 30

Combination instrument -bTRIPbF display ............................ 31

Combination instrument - coolant temperature indicator ...... 31

Opening filler cap ............................................................. 32

Closing filler cap .............................................................. 32

Fuel taps ......................................................................... 33

Handrails......................................................................... 33

Seat lock ......................................................................... 34

OWNER'S MANUAL .......................................................... 34

Tool set ........................................................................... 35

Passenger footrests ........................................................... 35

Shift lever........................................................................ 36

Foot brake pedal .............................................................. 37

Side stand ....................................................................... 37

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION......................................................................... 38

Advice on first use ............................................................ 38

Running in the engine....................................................... 39

Loading the vehicle .......................................................... 40

RIDING INSTRUCTIONS ....................................................... 42

Checks before putting into operation .................................. 42

Starting ........................................................................... 43

Starting up ...................................................................... 45

Shifting, riding ................................................................. 45

Braking ........................................................................... 48

Stopping, parking ............................................................. 49

CONTENTS 4

Refueling......................................................................... 51

GREASING AND SERVICE TABLE .......................................... 53

Important maintenance work to be carried out by an

authorized KTM workshop. ................................................ 53

Important maintenance work to be carried out by an

authorized KTM workshop. (as additional order)................... 55

MAINTENANCE WORK ON CHASSIS AND ENGINE ................. 56

Jacking up front of motorcycle ........................................... 56

Taking front from work stand ............................................. 56

Jacking up rear of motorcycle ............................................ 57

Take the rear from the work stand. ..................................... 57

Fork/shock absorber .......................................................... 58

Adjusting compression damping of fork

(690bSUPERMOTObR)....................................................... 58

Adjusting rebound damping of fork..................................... 59

Compression damping of shock absorber

(690bSUPERMOTObR)....................................................... 60

Adjusting the low-speed compression damping of the shock

absorber (690bSUPERMOTObR) ......................................... 60

Adjusting high-speed compression damping of the shock

absorber (690bSUPERMOTObR) ......................................... 61

Adjusting rebound damping of the shock absorber ............... 62

Bleeding fork legs............................................................. 63

Checking chain dirt .......................................................... 64

Cleaning the chain............................................................ 64

Checking the chain tension ............................................... 65

Adjusting chain tension..................................................... 66

Checking rear sprocket / engine sprocket for wear ................ 68

Checking chain wear ......................................................... 69

Checking brake discs ........................................................ 70

Adjusting basic position of handbrake lever......................... 71

Checking front brake fluid level.......................................... 71

Topping up the front brake fluidb

Brake linings.................................................................... 75

Checking the front brake linings......................................... 75

Checking free play of foot brake lever ................................. 76

Checking rear brake fluid level........................................... 77

Topping up brake fluid of front brakeb

Checking rear brake linings ............................................... 79

Removing front wheelb
Fitting front wheelb
Removing rear wheelb
Fitting rear wheelb
Checking the rear hub rubber dampersb

Tire condition checking ..................................................... 86

Checking tire air pressure .................................................. 87

Checking spoke tension (690bSUPERMOTO) ....................... 88

Removing the seat ............................................................ 89

Mounting the seat ............................................................ 89

Reinstalling the fuel tank .................................................. 90

Positioning the fuel tank ................................................... 91

Removing the batteryb
Installing the batteryb
Recharging the batteryb

Changing the main fuse .................................................... 95

Changing fuses of individual power consumers .................... 97

Removing headlight mask with headlight ............................ 99

Refitting the headlight mask with the headlight................. 100

Changing headlight bulb ................................................. 101

x .................................................. 80

x ....................................................... 81

x.................................................... 82

x ........................................................ 83

x ................................................... 92

x.................................................... 93

x ................................................. 93

x.................................... 72

x............................. 77

x .......................... 85

CONTENTS 5

Changing the parking lamp.............................................. 102

Changing flasher bulb ..................................................... 103

Checking headlamp setting.............................................. 104

Adjusting the headlight range .......................................... 105

Cooling system ............................................................... 106

Checking antifreeze and coolant level ............................... 106

Checking the coolant level............................................... 109

Draining coolantb
Filling/bleeding the cooling systemb

Adjusting basic position of clutch lever............................. 113

Checking/correcting fluid level of hydraulic clutch ............. 114

Checking play in gas Bowden cable .................................. 115

Adjusting play in gas Bowden cableb
Adjusting the handlebar angleb

Checking engine oil level................................................. 117

Changing engine oil and oil filter, cleaning oil
screensb

Draining engine oilb
Removing the oil filterb
Mounting oil filterb
Cleaning oil screensb
Filling up with engine oilb

Topping up engine oil ..................................................... 124

TROUBLESHOOTING.......................................................... 126

FLASHING CODE ............................................................... 129

CLEANING......................................................................... 132

Cleaning motorcycle ....................................................... 132

CONSERVATION FOR WINTER OPERATION ......................... 134

Conservation for winter operation ..................................... 134

x..................................................................... 118

x ........................................................ 110

x.............................. 111

x............................. 116

x..................................... 117

x .................................................... 118

x................................................ 120

x...................................................... 121

x................................................... 121

x ............................................ 123

STORAGE .......................................................................... 135

Storage.......................................................................... 135

Putting into operation after storage .................................. 136

TECHNICAL DATA - ENGINE ............................................... 137

Capacity - engine oil ....................................................... 138

Capacity - coolant........................................................... 138

TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........... 139

TECHNICAL DATA - CHASSIS ............................................. 142

Lighting equipment ........................................................ 143

Capacity - fuel................................................................ 144

TECHNICAL DATA - FORK................................................... 145

TECHNICAL DATA - SHOCK ABSORBER .............................. 146

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 148

SUBSTANCES.................................................................... 152

AUXILIARY SUBSTANCES................................................... 155

STANDARDS...................................................................... 157

INDEX ............................................................................... 158

MEANS OF REPRESENTATION 6

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Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

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 Indicates a proprietary name.

®

Name

Marke™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT NOTES 7

,03257$17127(6

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.

Info

The motorcycle is authorized for public road traffic in the homologous version only.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis 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.

Warranty

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 alterations to the vehicle.

Fuel, oils, etc.

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

IMPORTANT NOTES 8

Spare parts, accessories

For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop.
KTM accepts no liability for other products and any resulting damage or loss.

For the latestbKTMbPowerParts for your vehicle, see
International KTM Website: http://www.ktm.com

Transport

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

ದ Always place the vehicle on a firm and even surface.

Note

Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ದ Do not place the vehicle where there are flammable or explosive substances.

ದ Switch off the engine and remove the ignition key.
ದ Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential
problem for the environment and can lead to conflicts with other persons. 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 9

Warning notes

In your own interest, read the specified warning notes.

Info

Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may not
recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

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 of environmental damage.

OWNER'S MANUAL

ದ 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 10

ದ 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.

11

VIEW OF VEHICLE 12

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

View of vehicle, front left side

100187-10

VIEW OF VEHICLE 13

1 Combination instrument
2 Rear mirror
3 Clutch lever
4 Seat
5 Handrail
6 Front brake caliper
7 Left fuel tap
8 Shift lever
9 Engine number
10 Side stand

VIEW OF VEHICLE 14

View of vehicle, rear right side

100188-10

VIEW OF VEHICLE 15

1 Seat lock
2 Light switch, headlight flasher switch, indicator switch, horn
3 Filler cap
4 Emergency OFF switch, electric starter button
5 Hand brake lever
6 Chassis number, type label
7 Rear brake caliper
8 Passenger footrests
9 Foot brake pedal
10 Engine oil level viewer
11 Right fuel tap

LOCATION OF SERIAL NUMBERS 16

/2&$7,212)6(5,$/ 180%(56



Chassis number/type label

The chassis numberb is stamped on the steering head on the right.
The type labelb

500006-01

Key number

The key numberb can be found on the istbKEYCODECARD.
You need the key number to order a spare key. Keep thebKEYCODECARD in a safe place.

 is located under the chassis number.

100179-10

LOCATION OF SERIAL NUMBERS 17

Engine number

The engine numberb is stamped on the left side of the engine under the engine sprocket.

500001-01

Fork part number

The fork part numberb is stamped on the inner side of the fork stub.

100184-10

LOCATION OF SERIAL NUMBERS 18

Shock absorber part number

The shock absorber part numberb is stamped on the top of the shock absorber above the
adjusting ring on the engine side.

100185-10

OPERATING ELEMENTS 19

23(5$7,1*(/(0(176



Clutch lever

(690bSUPERMOTO)

The clutch leverb

100113-10

(690bSUPERMOTObR)

The clutch leverb

The clutch is hydraulically operated and self-adjusting.

100114-10

 is fitted on the left side of the handlebar.

 is fitted on the left side of the handlebar.

OPERATING ELEMENTS 20

Hand brake lever

The hand brake leverb is located on the right side of the handlebar and operates the front
wheel brake.
The hand brake lever operates the front brake.

500018-01

Light switch

The light switchb is fitted on the left side of the handlebar.

Possible states

Low beam on ದbLight switch is turned downwards. In this position, the low
beam and tail light are switched on.

High beam on ದbLight switch is turned upwards. In this position, the high
beam and the tail light are switched on.

500020-01

OPERATING ELEMENTS 21

Headlight flasher switch

The headlight flasher switchb is fitted on the left side of the handlebar.

Possible states

• Headlight flasher switch in neutral position

• Headlight flasher switch pressed ದbIn this position, the headlight flasher (high beam)
is actuated.

500020-11

Flasher switch

The flasher switchb is fitted on the left side of the handlebar.

Possible states

Flasher light off
Flasher light, left, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.

Flasher light, right, on ದbFlasher 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

Horn

The horn buttonb is fitted on the left side of the handlebar.

Possible states

• Horn buttonb in neutral position

• Horn buttonb pressed ದbThe horn is operated in this position.

500021-11

Ignition/steering lock

The ignition/steering lockb is located in front of the upper triple clamp.

Possible states

Ignition off ದbIn 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 on ದbIn this position, the ignition circuit is closed, and the engine
can be started.

Steering locked ದbIn this position, the ignition circuit is interrupted and the
steering locked. The ignition key can be removed.

500019-01

OPERATING ELEMENTS 23

Emergency OFF switch

The emergency OFF switchb is fitted on the left side of the handlebar.

Possible states

Emergency OFF switch on ದbThis position is necessary for operation as the
ignition circuit is closed.

Emergency OFF switch off ದbIn this position, the ignition circuit is inter­rupted, a running engine stops, and the engine cannot be started.

500022-10

Electric starter button

The electric starter buttonb is fitted on the right side of the handlebar.

Possible states

• Electric starter buttonb in basic position

• Electric starter buttonb pressed ದbIn this position, the electric starter is actuated.

500022-11

OPERATING ELEMENTS 24

Combination instrument

The combination instrument is attached in fromt of the handlebar.
The combination instrument is divided into 4 function areas.

bFunction buttons
 Tachometer
 Indicator lights
 Display

700116-01

Combination instrument - function buttons

Press thebMODEbbuttonb to change the display mode.
Possible display modes are total distance covered (ODO), tripmasterb1b(TRIPb1) and tripmas­terb2b(TRIPb2).
Press thebSETbbuttonb
Buttonb

 has no function.

 to reset tripmasterb1b(TRIPb1) and tripmasterb2b(TRIPb2)tob0.0.

700117-01

OPERATING ELEMENTS 25

Combination instrument - tachometer

The tachometerb displays the engine speed in revolutions per minute.
The red markingb

100118-10

Combination instrument - control lamps

The indicator lamps provide additional information on the operating state of the motorcycle.

Possible states

 shows the excess engine speed range.

Flashing indicator flashes green in flash rhythm ದbFlasher light is switched
on.

Idling speed indicator lamp lights up green ದbTransmission is in neutral.

High beam indicator lamp lights up blue ದbHigh beam is switched on.

100119-10

Temperature warning lamp lights up red ದbCoolant has reached a critical
value.

Fuel level warning lamp lights up orange ದbFuel level has reached the reserve
mark. Display switches tobTRIPbF.

FIbwarning lamp (MIL) lights/flashes orange ದbThe OBD has detected an
emission- or safety-critical error.

OPERATING ELEMENTS 26

Battery warning lamp lights up ದbVoltage in electrical system too low.

Combination instrument - Display

When you switch on the ignition, all display segments light up for a second as a function
test.

700118-01

LEnGTth

Following the display function test, the wheel circumferencebLEnGth is shown for one sec­ond.

Info

1870 mm corresponds to the circumference of the 17" front wheel with a series pro­duction tire.

700119-01

The display then changes to the last selected mode.

OPERATING ELEMENTS 27

Combination instrument - speed display

The speedb is displayed in kilometers per hourbkm/h or miles per hourbMph.

700114-01

Setting kilometers or miles

Info

If you change the unit, the ODO value is retained and converted accordingly.
Making the setting according to the country.

Condition

The motorcycle is standing.

OPERATING ELEMENTS 28

ದ Turn the ignition key to the positionb .
ದ Press thebMODEbbutton several times until thebODO display mode is active.
ದ Keep the MODEbbutton pressed until the display mode changes frombKm/h to Mph or

from Mph to Km/h.
Specification

Activation duration of MODEbbutton 10bs

700120-01

Combination instrument - time

The time is shown in areab of the display.

Info

The time must be adjusted after the battery is disconnected or the fuse is changed.

700115-01

Setting the clock

Condition

The motorcycle is standing.

OPERATING ELEMENTS 29

ದ Turn the ignition key to the positionb .
ದ Press thebMODEbbutton several times until thebODO display mode is active.
ದ Keep thebMODEbbutton and thebSETbbutton pressed simultaneously.

The time begins to flash.

ದ Press thebMODEbbutton to adjust the hour.
ದ Press thebSETbbutton to adjust the minute.
ದ Keep thebMODEbbutton and thebSETbbutton pressed simultaneously.

700115-01

Combination instrument -bODO display

InbODO mode, the total distance covered is shown in kilometers or miles.

700120-01

The time is set.

Info

This value remains intact even if the battery is disconnected and/or the fuse blows.

Combination instrument - setting/resettingbTRIPb1 display

Info

The tripmasterbTRIPb1 operates constantly and counts up tob999.9.
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 30

ದ Turn the ignition key to the positionb .
ದ Press thebMODEbbutton several times until thebTRIPb1 display mode is active.
ದ Keep thebSETbbutton pressed.

ThebTRIPb1 display is atb0.0.

700121-01

Combination instrument - setting/resettingbTRIPb2 display

Info

The tripmasterbTRIPb2 operates constantly and counts up tob999.9.
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.

ದ Turn the ignition key to the positionb .
ದ Press thebMODEbbutton several times until thebTRIPb2 display mode is active.
ದ Keep thebSETbbutton pressed.

ThebTRIPb2 display is atb0.0.

700122-01

OPERATING ELEMENTS 31

Combination instrument -bTRIPbF display

When the fuel level reaches the reserve mark, the display automatically changes tobTRIPbF
and begins to count fromb0.0, regardless of which display mode was previously active.

Info

Parallel to thebTRIPbF display, the fuel warning light begins to light up.

700123-01

Combination instrument - coolant temperature indicator

The temperature indicator in the display consists of 12 bars. 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

• Engine cold ದbup to four bars.

• Engine at normal operating termperature ದbfrom five to eleven bars.

• Engine hot ದball twelve bars flash.

700124-01

OPERATING ELEMENTS 32

Opening filler cap

ದ Lift the cover of the filler capb and insert the ignition key.
ದ Turn the ignition key 90° counterclockwise and remove the filler cap.

Info

The filler cap has a tank air vent system.

500023-10

Closing filler cap

ದ Put the filler cap back on and turn the ignition key 90° clockwise.
ದ Remove the ignition key and fold down the cover.

500023-01

OPERATING ELEMENTS 33

Fuel taps

The fuel tapsb are located on the left/right under the fuel tank.

Possible states

• Fuel supply closed ದbThe knurled screws are turned clockwise as far as possible. The
level cannot be compensated and no fuel can flow out of the fuel tank.

• Fuel tap open ದbThe knurled screws are turned counterclockwise as far as possible.
The level can be compensated and the fuel can flow out of the fuel tank.

100178-10

Handrails

The handrailsb are used for moving the motorcycle around.
When you have a passenger, the passenger can hold on the handrails during the journey.

500030-10

OPERATING ELEMENTS 34

Seat lock

The seat lockb is located to the right of the seat.
You can lock it with the ignition key.

100108-10

OWNER'S MANUAL

You can find the owner's manualb in its protective case on the underside of the seat.

500031-10

OPERATING ELEMENTS 35

Tool set

The tool setb is located in the storage compartment under the seat.

500032-10

Passenger footrests

The passenger footrestsb can be folded in and out.

Possible states

• Passenger footrests folded up ದbFor operation without a passenger.

• Passenger footrests folded down ದbFor operation with a passenger.

500036-10

OPERATING ELEMENTS 36

Shift lever

The shift leverb is mounted on the left side of the engine.

100110-10

The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

100111-10

OPERATING ELEMENTS 37

Foot brake pedal

The footbrake pedalb is located in front of the right footrest.
The footbrake pedal operates the rear brake.

100183-10

Side stand

The side standb is coupled with the safety electric starter system - see the riding instruc­tions.

Possible states

• Side stand folded out ದbThe vehicle can be supported on the side stand. The safety
electric starter system is active.

• Side stand folded in ದbThis position is mandatory for all journeys. The safety electric
starter system is inactive.

500034-10

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 38

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

Advice on first use

Danger

Danger of accidentsಘDanger from inadequate traffic experience.

ದ Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

Warning

Risk of injuryಘRisk of injury by missing/inadequate protective clothing.

ದ 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 crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.

ದ 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 accidentsಘUncontrollable handling behavior caused by non-approved tires/wheels.

ದ Use only tires/wheels approved by KTM with the corresponding speed index.

Warning

Danger of accidentsಘReduced road grip with new tires.

ದ 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 accidentsಘBrake system failure.

ದ If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your

foot off the foot brake pedal if you do not want to brake.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 39

Info

When using your vehicle, remember that others may feel disturbed by excessive noise.

ದ 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.

ದ Before your first trip, read the entire operating instructions carefully.
ದ Get to know the operating elements.
ದ adjust the basic position of clutch lever. ( P. 113)
ದ adjust the basic position of handbrake lever. ( P. 71)
ದ Adjust the basic position of the footbrake lever.
ದ 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.

ದ Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
ದ Do not make any changes to the vehicle, and use only KTM approved parts.

Info

Parts from other manufacturers can reduce the operational safety of the vehicle.

ದ Run the engine in.

Running in the engine

ದ During the running-in phase, do not exceed the specified engine speed and engine performance.

Specification

Maximum engine speed

During the first: 1,000bkm (621.4bmi) 6,000brpm
After the first: 1,000bkm (621.4bmi) 7,800brpm

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 40

ದ Avoid fully opening the throttle!

Loading the vehicle

Warning

Danger of accidentsಘUnstable riding behavior.

ದ 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 accidentsಘUnstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.

ದ Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.

Warning

Danger of accidentsಘUnstable handling characteristics at high speed.

ದ Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage.

Maximum speed with baggage 130bkm/h (80.8bmph)

Warning

Danger of accidentsಘRisk of breakage of suitcase system.

ದ If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.

Warning

Danger of accidentsಘPoor visibility for other road users due to slipped baggage.

ದ If the 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 accidentsಘChanged handling characteristics and longer stopping distance with excessive payload.

ದ Adapt your speed according to your payload.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 41

Warning

Danger of accidentsಘUnstable handling characteristics due to slipped baggage.

ದ Check the way your baggage is fixed regularly.

Warning

Danger of burnsಘA hot exhaust system can burn baggage.

ದ Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.

ದ If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu-

tion between the front and rear wheels.

ದ Do not exceed the overall maximum permitted weight and the axle loads.

Specification

Maximum permissible overall weight 350bkg (772blb.)
Maximum permissible front axle load 150bkg (331blb.)
Maximum permissible rear axle load 200bkg (441blb.)

RIDING INSTRUCTIONS 42

5,',1*,16758&7,216



Checks before putting into operation

Info

Make sure that the motorcycle is in a perfect technical condition before use.
In the interests of riding safety, make a habit of making a general check before you ride.

ದ Check the engine oil level. ( P. 117)
ದ Check the engine for loss of oil.
ದ Check the fuel level.
ದ Bleed fork legs. ( P. 63)

Specification

all 1,000bkm (621.4bmi)

ದ Check the chain tension. ( P. 65)
ದ Clean the chain. ( P. 64)
ದ Check the tire condition. ( P. 86)
ದ Checking the tire air pressure. ( P. 87)
ದ Check the front brake brake fluid level. ( P. 71)
ದ Check the rear brake fluid level. ( P. 77)
ದ Check the front brake linings. ( P. 75)
ದ Check the rear brake linings. ( P. 79)
ದ Check brake system function.
ದ Check the coolant level. ( P. 109)
ದ Check that all operating elements are correctly adjusted and free to move.
ದ Check the functioning of the electrical equipment.
ದ Check that baggage is correctly secured.
ದ Sit on the motorcycle and check the rear mirror setting.

RIDING INSTRUCTIONS 43

Starting

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.

ದ 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 accidentsಘIf the vehicle is operated with a discharged battery or without a battery, electronic components and safety

equipment may be damaged.

ದ Never operate the vehicle with a discharged battery or without a battery.

Note

Engine failureಘHigh engine speeds in cold engines have a negative effect on the service life of the engine.

ದ Always warm up the engine at low engine speeds.

RIDING INSTRUCTIONS 44

ದ Turn the emergency OFF switch to thebpositionb .
ದ Turn the ignition key to the positionb .

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.

ದ Shift gear to neutral.

The green idling speed indicator lampbNb

ದ Press the electric starter buttonb .

Info

Do not press the electric starter button until the combination instrument func­tion 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.

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

go.

 lights up.

100109-10

RIDING INSTRUCTIONS 45

Starting up

ದ Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting, riding

Warning

Danger of accidentsಘAn abrupt load alterations can cause the vehicle to get out of control.

ದ Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.

Warning

Danger of accidentsಘIf you change down at high engine speed, the rear wheel can lock up.

ದ Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.

Warning

Danger of accidentsಘMalfunctions caused by incorrect ignition key position.

ದ Do not change the ignition key position during a journey.

Warning

Danger of accidentsಘDistraction from traffic activity by adjustments to the vehicle.

ದ Make all adjustments when the vehicle is at a standstill.

Warning

Risk of injuryಘThe passenger must be capable of sitting correctly on the passenger seat.

ದ 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 accidentsಘDanger of accidents caused by dangerous driving.

ದ Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible.

RIDING INSTRUCTIONS 46

Warning

Danger of accidentsಘReduced road grip with cold tires.

ದ 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 accidentsಘReduced road grip with new tires.

ದ 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 accidentsಘUnstable riding behavior.

ದ 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 accidentsಘUnstable handling characteristics due to slipped baggage.

ದ Check the way your baggage is fixed regularly.

Warning

Danger of accidentsಘAfter a fall, check the vehicle.

ದ After a fall, check the vehicle as usual before putting it into operation.

Note

Engine failureಘUnfiltered intake air has a negative effect on the service life of the engine.

ದ Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

RIDING INSTRUCTIONS 47

Note

Engine failureಘOverheating of engine.

ದ 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.

ದ When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
ದ Release the throttle while simultaneously pulling the clutch lever, shift into the next

gear, release the clutch and open the throttle.

Info

For the positions of the 6 forward gears, see the illustration. The neutral or idle
position is between the first and 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

100111-10

ದ When you reach maximum speed after fully opening the throttle, turn back the throttle

ದ Open the throttle only as far as the road and weather conditions permit. Particularly in

ದ To shift down, brake if necessary and close the throttle at the same time.
ದ Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open

light up.

to about 3/4 of its range; the speed hardly drops, but the fuel consumption falls consid­erably.

bends, do not shift and open the throttle only very cautiously.

the throttle or shift again.

RIDING INSTRUCTIONS 48

ದ 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.

ದ Switch off the engine if you expect to be standing for a long time.
ದ If the FIbwarning lamp (MIL) starts to light up during the journey, stop immediately. If

you shift to neutral, thebFIbwarning lamp (MIL) begins to flash.

Info

From the flash rhythm, you can deduce a two-digit number, the so-called flash
code. The flash code tells you which component is affected by a fault.

Braking

Warning

Danger of accidentsಘIf you brake too hard, the wheels can lock.

ದ Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidentsಘReduced braking due to wet or dirty brakes.

ದ Clean or dry dirty or wet brakes by riding and braking gently.

Warning

Danger of accidentsಘReduced braking caused by spongy pressure point of front or rear brake.

ದ Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘBrake system failure.

ದ If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your

foot off the foot brake pedal if you do not want to brake.

RIDING INSTRUCTIONS 49

Warning

Danger of accidentsಘLonger stopping distance due to higher overall weight.

ದ Take the longer stopping distance into account when carrying a passenger and baggage.

Warning

Danger of accidentsಘDelayed brake action on salted roads.

ದ Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by brak-

ing.

ದ To brake, release the throttle and operate the front and rear brakes simultaneously.
ದ On sandy, wet or slippery surfaces, use the rear brake.
ದ Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
ದ 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 misappropriationಘUsage by unauthorized persons.

ದ 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.

Warning

Danger of burnsಘSome vehicle components get very hot when the machine is driven.

ದ 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 damageಘDanger of damage by the vehicle running away or falling over.

RIDING INSTRUCTIONS 50

ದ Always place the vehicle on a firm and even surface.

Note

Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ದ Do not place the vehicle where there are flammable or explosive substances.

Note

Material damageಘDamage and destruction of components by excessive load.

ದ 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.

ದ Brake the motorcycle.
ದ Shift gear to neutral.
ದ Turn the ignition key to thebpositionb .

Info

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.

ದ Park the motorcycle on a hard surface.
ದ Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.
ದ Turn the steering to the left, press the ignition key down to the positionb and turn it to the positionb . To make locking the steering

easier, move the handlebar a little to the left and right. Remove the ignition key.

RIDING INSTRUCTIONS 51

Refueling

Danger

Fire hazardಘFuel can easily catch fire.

ದ 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.

ದ 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 poisoningಘFuel is poisonous and a health hazard.

ದ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately

with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc­tor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazardಘImproper handling of fuel is a danger to the environment.

ದ Do not allow fuel to get into the ground water, the ground, or the sewage system.

Info

This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel
only.

RIDING INSTRUCTIONS 52

ದ Switch off engine.
ದ Open the filler cap. ( P. 32)
ದ Fill the fuel tank with fuel up to measurementb

Specification

Measurement ofb

 50bmm (1.97bin)

.

100120-10

100121-10

Fuel tank content 13.5bl

(3.57bUSbgal)

ದ Close the filler cap. ( P. 32)
ದ Press thebSETb function button for 2 seconds.

The fuel level warning lampb
previous display mode.

 switches off. TRIPbF is set to 0 and appears in the

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( P. 152)

Info

If you do not press thebSETb function button, the reset takes place automati­cally after about 3 minutes.

GREASING AND SERVICE TABLE 53

*5($6,1*$1'6(59,&( 7$%/(



Important maintenance work to be carried out by an authorized KTM workshop.

K10N K50A K100A J1A J2A

Engine

Fuel injection

Attachments Check the cooling system for leakage. • • • • •

Change engine oil and oil filter, clean oil screens.b
Check and adjust valve clearance.b
Check engine mounting screws for tightness. • • • • •
Replace spark plug. •
Check engine bolts accessible from outside for tightness. • • • • •
Check connection boots for cracks and leakage.b
Read out the error memory with a KTM diagnostic tool.b
Check fuel hoses, SLS hoses and vent hoses for damage, correct fit-

ting and leaks.b
Clean, check and grease the O-ring of the fuel hose connection.b
Check the cable harness of the throttle valve body for damage and cor-

rect positioning.b

Check the antifreeze and coolant level. ( P. 106) • • • • •
Check the functioning of the radiator fan.b
Check the exhaust system for leaks and correct fitting and check that

the exhaust clamps are tight.b
Check Bowden cables for damage, smooth operation, routing without

sharp bends and setting.
Check/correct the fluid level of the hydraulic clutch. ( P. 114) • • • •
Check air filter and change if necessary. Clean the air filter box.b
Check cables for damage and routing without sharp bends.b
Check the headlamp setting. ( P. 104) • • • • •

x

x

x

x

x

x ( P. 118)

x

x

x

x

x

•••••

••

•••

•••••

•••••

••••

•••

•••••

•••••

•••••

••••

•••••

GREASING AND SERVICE TABLE 54

K10N K50A K100A J1A J2A

Attachments Check the functioning of the electrical equipment. • • • • •

Check screws and nuts for tightness. • • • • •

Brakes Check the front brake linings. ( P. 75) • • • • •

Check the rear brake linings. ( P. 79) • • • • •
Check the brake discs. ( P. 70) • • • • •
Check the front brake brake fluid level. ( P. 71) • • • • •
Check the rear brake fluid level. ( P. 77) • • • • •
Change brake fluid.b
Check brake lines for damage and leakage. • • • • •
Check the free play of the foot brake lever. ( P. 76) • • • • •
Check braking. • • • • •
Check screws and guide bolts of brake system for tightness.b

Chassis

Wheels Check the spoke tension. (690bSUPERMOTO) ( P. 88) • • • • •

Check shock absorber and fork for leakage and functioning.bx
Clean dust boots of fork legs.b
Bleed fork legs. ( P. 63) • • • • •
Check swingarm bearing.b
Check play of steering head bearing.b
Check all screws to see if they are tight. • • • • •
Grease ProತLever deflector.b

Check rim run-out.b
Check the tire condition. ( P. 86) • • • • •
Checking the tire air pressure. ( P. 87) • • • • •

x

x

x

x

x

x

x

•••••

•••••

••••

•••••

•••••

•••••

•

•

GREASING AND SERVICE TABLE 55

K10N K50A K100A J1A J2A

Wheels Check the chain wear. ( P. 69) • • • • •

Check rear sprocket / engine sprocket for tightness. • • • • •
Check rear sprocket / engine sprocket for wear. ( P. 68) • • • • •
Check the chain tension. ( P. 65) • • • • •
Clean the chain. ( P. 64) • • • • •
Check wheel bearing for play.b
Checking the rear hub rubber dampers.b

K10N: after 1,000 km (621.4 mi)
K50A: every 5,000 km (3,107 mi)
K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

Carry out a complete fork service.b
Carry out a complete shock absorber service.b
Clean and grease steering head bearing and sealing elements.b
Treat electric contacts with contact spray. ••
Clean the battery terminals and treat them with contact grease. • •
Change coolant.b

x

x

x

x ( P. 85)

x

x

••••

••••

K100A J1A J2A

••

••

•

•

K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

0$,17(1$1&(:25. 21&+$66,6 $1'(1*,1(



Jacking up front of motorcycle

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

ದ Always place the vehicle on a firm and even surface.

ದ Jack up the rear of the motorcycle. ( P. 57)
ದ Move the handlebar to the straight-ahead position. Align the work stand to the front

with the adapters to the fork legs.

Work stand front (61029055300)

Info

Always jack up the rear of the motorcycle first.

ದ Jack up the front of the motorcycle.

500096-01

Taking front from work stand

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

ದ Always place the vehicle on a firm and even surface.

ದ Secure the motorcycle against falling over.
ದ Remove the work stand at the front.

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

Jacking up rear of motorcycle

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

ದ Always place the vehicle on a firm and even surface.

ದ Insert the work stand adapter in the work stand and screw it into the link forks.

Work stand adapter (61029055110)
Work stand rear (61029055100)

ದ Stand the motorcycle upright, align the work stand to the rear, and jack up the motorcy-

cle.

500095-01

Take the rear from the work stand.

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

ದ Always place the vehicle on a firm and even surface.

ದ Secure the motorcycle against falling over.
ದ Remove the work stand from the rear and lean the vehicle on the side stand.

MAINTENANCE WORK ON CHASSIS AND ENGINE 58

Fork/shock absorber

The fork and the shock absorber offer many options of adapting the chassis to your riding
style and the payload.

Info

To help you adapt the vehicle, we have summarized our findings in Tableb. You
can find the table on the air filter box under the seat.

These adjustments should be understood as a guideline and should always be the basis

100177-10

Adjusting compression damping of fork (690bSUPERMOTObR)

Info

The hydraulic compression damping determines the fork suspension behavior.

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.

ದ Turn adjusting screwsb clockwise until they stop.

Info

The adjusting screwsb are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

100122-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 59

ದ Turn back counterclockwise the number of clicks corresponding to the fork type.

Specification

Compression damping

Comfort 20bclicks
Standard 15bclicks
Sport 10bclicks
full payload 10bclicks

Info

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

Adjusting rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

ದ Turn adjusting screwsb clockwise until they stop.

Info

The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.

100123-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

ದ Turn back counterclockwise the number of clicks corresponding to the fork type.

Specification

Rebound damping

Comfort 20bclicks
Standard 15bclicks
Sport 10bclicks
full payload 10bclicks

Info

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

Compression damping of shock absorber (690bSUPERMOTObR)

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 (690bSUPERMOTObR)

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-

nance on it yourself.

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

MAINTENANCE WORK ON CHASSIS AND ENGINE 61

ದ Turn the adjusting screwb clockwise with a screwdriver until it stops.

Info

Do not loosen nutb!

ದ Turn back counterclockwise the number of clicks corresponding to the shock absorber

type.
Specification

Compression damping, low-speed

100125-10

Adjusting high-speed compression damping of the shock absorber (690bSUPERMOTObR)

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-

nance on it yourself.

Comfort 20bclicks
Standard 15bclicks
Sport 10bclicks
full payload 10bclicks

Info

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

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

ದ Turn the adjusting screwb clockwise with an open-ended spanner until it stops.

Info

Do not loosen nutb!

ದ Turn back counterclockwise the number of turns corresponding to the shock absorber

type.
Specification

Compression damping, high-speed

100126-10

Adjusting rebound damping of the shock absorber

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-

nance on it yourself.

Comfort 2bturns
Standard 1.5bturns
Sport 1bturn
full payload 1bturn

Info

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 63

ದ Turn the adjusting screwb clockwise until it stops.
ದ Turn back counterclockwise the number of clicks corresponding to the shock absorber

type.
Specification

Rebound damping

Comfort 20bclicks
Standard 15bclicks

100127-10

Bleeding fork legs

ದ Lean the motorcycle on the side stand.
ದ Remove bleeder screwsb briefly.

ದ Mount and tighten bleeder screws.

Sport 10bclicks
full payload 10bclicks

Info

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

Any excess pressure escapes from the interior of the fork.

Info

Carry out this action on both fork legs.

100124-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 64

Checking chain dirt

ದ Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

ದ Clean the chain. ( P. 64)

Cleaning the chain

Warning

Danger of accidentsಘOil or grease on the tires reduces their grip.

ದ Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ 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.

ದ Clean the chain regularly.
ದ Rinse off loose dirt with a soft jet of water.
ದ Remove old grease remains with chain cleaner.

Chain cleaner ( P. 155)

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

ದ After drying, apply chain spray.

Onroad chain spray ( P. 155)

Checking the chain tension

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ 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 chain tension and adjust if necessary.

MAINTENANCE WORK ON CHASSIS AND ENGINE 66

ದ Lean the motorcycle on the side stand.
ದ Shift gear to neutral.
ದ Push the chain upwards near the vertical rib of the swingarm and measure the chain

tensionb

» If the chain tension does not meet specifications:

100130-10

Adjusting chain tension

.

Info

The upper chain sectionb must be taut.
Chain wear is not always even, so you should repeat this measurement at differ­ent chain positions.

Chain tension 5bmm (0.2bin)

ದ Adjust the chain tension. ( P. 66)

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ 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 chain tension and adjust if necessary.

MAINTENANCE WORK ON CHASSIS AND ENGINE 67

ದ Lean the motorcycle on the side stand.
ದ Shift gear to neutral.
ದ Loosen nutb
ದ Loosen nutsb
ದ Adjust the chain tension by turning the adjusting screwsb

Specification

Chain tension 5bmm (0.2bin)
Turn the adjusting screwsb

chain adjustersb
rear wheel is then correctly aligned.

.

.

 left and right.

 left and right so that the markings on the left and right

 are in the same position relative to the reference marksb. The

Info

The upper chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at differ­ent chain positions.

100131-10

ದ Tighten nutsb
ದ Make sure that the chain adjustersb
ದ Tighten nutb

Specification

Nut, rear wheel spindle M25x1.5 90bNm (66.4blbfbft)

.

 are fitted correctly on the adjusting screwsb.

.

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjustersb

 can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE 68

Checking rear sprocket / engine sprocket for wear

ದ Check rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

ದ Replace rear sprocket / engine sprocket.

Info

The engine sprocket, rear sprocket and chain should always be replaced
together.
For safety reasons, the chain has no chain joint. Always have the chain
replaced in an authorized KTM workshop, where the necessary chain

100132-10

ದ Check chain guides for tightness and wear.

rivet tool is available.

MAINTENANCE WORK ON CHASSIS AND ENGINE 69

Checking chain wear

ದ Shift into neutral, pull the lower chain section with the specified weightb.

Specification

Weight of chain wear measurement 15bkg (33blb.)

A

B

1 2 3 16 17 18

100133-10

ದ Measure the distanceb

Info

Chain wear is not always even, so you should repeat this measurement at differ­ent chain positions.

Maximum distanceb
chain section

» If the distanceb

ದ Have the chain changed.

 is greater than the specified measurement:

Info

When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
For safety reasons, the chain has no chain joint. Always have the chain
changed in an authorized KTM workshop, where the necessary tool is
available.

 of 18 chain links in the lower chain section.

 at the longest

272bmm (10.71bin)

MAINTENANCE WORK ON CHASSIS AND ENGINE 70

Checking brake discs

Warning

Danger of accidentsಘReduced braking due to worn brake discs.

ದ Worn brake discs should be replaced immediately in an authorized KTM workshop.

ದ Check the thickness of the front and rear brake discs at several places on the disc to

100135-10

see if it conforms to measurementb

Info

Wear reduces the thickness of the brake disc around the area used by the brake

.

linings.

Wear limit of brake discs (690bSUPERMOTO)

front 4.0bmm (0.157bin)
Rear 4.5bmm (0.177bin)

Wear limit of brake discs (690bSUPERMOTObR)

front 3.6bmm (0.142bin)
Rear 4.5bmm (0.177bin)

» If the brake disc thickness is less than the specified value:

ದ Change the brake disc.

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 71

Adjusting basic position of handbrake lever

ದ Adjust the basic setting of the handbrake lever to your hand size by turning adjusting

.

wheelb

Info

Pull the brake lever forwards and turn the adjusting wheel.
Do not make any adjustments while riding!

100117-10

Checking front brake fluid level

Warning

Danger of accidentsಘBrake system failure.

ದ 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 accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

MAINTENANCE WORK ON CHASSIS AND ENGINE 72

(690bSUPERMOTO)

100136-10

100134-10

Topping up the front brake fluidbx

ದ The brake fluid level must not fall below the center of the level viewerb

brake fluid reservoir is vertical.
» If the brake fluid level is lower than the center of the level viewer:

ದ

Top up the brake fluid of the front brake.b

(690bSUPERMOTObR)

ದ The brake fluid level must not fall below thebMIN markingb

reservoir is vertical.
» If the brake fluid is below thebMIN marking:

ದ

Top up the brake fluid of the front brake.b

x ( P. 72)

 when the brake fluid

x ( P. 72)

 when the

Warning

Danger of accidentsಘBrake system failure.

ದ 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 73

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends DOTb5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOTb4 brake fluid and provides
greater safety for high demands.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

ದ Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

MAINTENANCE WORK ON CHASSIS AND ENGINE 74

(690bSUPERMOTO)

100180-10

100181-10

ದ Remove screwsb
ದ Remove the coverb
ದ Top up brake fluid to levelb

Specification

Measurement ofb

Brake fluid DOT 5.1 ( P. 152)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

(690bSUPERMOTObR)

ದ Loosen screwb.
ದ Remove the coverb
ದ Top up the brake fluid tobMAX level.
ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

.

 with membraneb.

.

 5bmm (0.2bin)

 with membraneb.

MAINTENANCE WORK ON CHASSIS AND ENGINE 75

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.

Checking the front brake linings

Warning

Danger of accidentsಘReduced braking due to worn brake linings.

ದ Worn brake linings should be replaced immediately in an authorized KTM workshop.

Note

Danger of accidentsಘReduced braking due to damaged brake discs.

ದ If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly re-

duced and the brake discs are destroyed.

MAINTENANCE WORK ON CHASSIS AND ENGINE 76

ದ Check the brake linings for minimum thicknessb.

» Minimum thicknessb

If the minimum thickness is less than specified:
ದ Worn brake linigs should be replaced immediately in an authorized KTM work-

shop.

100137-10

Checking free play of foot brake lever

Warning

Danger of accidentsಘBrake system failure.

ದ 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.

ದ Disconnect springb.
ದ Move the foot brake lever backwards and forwards between the end stop and the foot

brake cylinder piston bracket and check free playb
Specification

Free play at foot brake lever 3… 5bmm (0.12… 0.2bin)

: ุb1bmm (ุb0.04bin)

.

100182-10

» If the free travel does not meet specifications:

ದ Have the free travel corrected in an authorized KTM workshop.

ದ Reconnect springb

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 77

Checking rear brake fluid level

Warning

Danger of accidentsಘBrake system failure.

ದ 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 accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

ದ Stand the vehicle upright.
ದ Check the brake fluid level in the brake fluid reservoir.

100138-10

» If the fluid level reaches thebMINbmarkingb

ದ

Top up the brake fluid of the rear brake.b

:

x ( P. 77)

Topping up brake fluid of front brakebx

Warning

Danger of accidentsಘBrake system failure.

ದ 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 78

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends DOTb5.1 brake fluid frombMotorex®. This has a higher wet boiling point than DOTb4 brake fluid and provides
greater safety for high demands.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 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 79

ದ Stand the vehicle upright.
ದ Remove screw coverb
ದ Top up the brake fluid tobMAX level.

Brake fluid DOT 5.1 ( P. 152)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Refit screw with membrane.

 with membraneb.

100176-10

Checking rear brake linings

Info

Clean up overflowed or spilt brake fluid immediately with water.

Warning

Danger of accidentsಘReduced braking due to worn brake linings.

ದ Worn brake linings should be replaced immediately in an authorized KTM workshop.

Note

Danger of accidentsಘReduced braking due to damaged brake discs.

ದ If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly re-

duced and the brake discs are destroyed.

MAINTENANCE WORK ON CHASSIS AND ENGINE 80

ದ Check the brake linings for minimum thicknessb.

» Minimum thicknessb

If the minimum thickness is less than specified:
ದ Worn brake linings should be replaced immediately in an authorized KTM work-

shop.

100139-10

Removing front wheelbx

ದ Jack up the rear of the motorcycle. ( P. 57)
ದ Jack up the front of the motorcycle. ( P. 56)
ದ Remove screwb and spacing sleeveb.
ದ Press back the brake linings with a light lateral tilting of the brake caliper on the brake

disc. Pull the brake caliper carefully back from the brake disc and hang it to one side.

Info

Do not pull the handbrake lever when the brake caliper is removed.

: ุb1bmm (ุb0.04bin)

100140-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 81

ದ Loosed screwb and screwb.
ದ Screw out screwb

dle out of the fork stub. Remove screwb

Warning

Danger of accidentsಘReduced braking due to damaged brake discs.

ದ Always lay the wheel down in such a way that the brake disc is not damaged.

 about 6 turns, press your hand on the screw to push the wheel spin-

.

Fitting front wheelbx

100141-10

100142-10

ದ Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the

fork.

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

ದ Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Clean and grease the thread of the wheel spindle and screwb

Long-life grease ( P. 155)

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

tighten screwb
Specification

Screw, front wheel spindle M24x1.5 40bNm (29.5blbfbft)

ದ Position the brake caliper and check that the brake linings are seated correctly.

.

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 82

Removing rear wheelbx

100168-10

ದ Position the spacing sleevesb

. Mount and tighten screwsb.

Specification

®

Screw, front brake caliper M10x1.25 45bNm

Loctite

243™

(33.2blbfbft)

ದ Operate the hand brake lever several times until the brake pads are lying correctly on

the brake disc.

ದ Take the front from the work stand. ( P. 56)
ದ Pull the front wheel brake and push down hard on the fork several times to align the

fork legs.

ದ Fully tighten screwb

.

Specification

Screw, fork stub M8 15bNm (11.1blbfbft)

ದ Taking rear from work stand. ( P. 57)

ದ Jack up the rear of the motorcycle. ( P. 57)
ದ Remove nutb. Remove chain adjusterb. Holding the rear wheel, withdraw the wheel

spindleb

.

ದ Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.

100144-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 83

ದ Pull the rear wheel and brake caliper supportb together to the rear until you can swing

the brake caliper support to the side.

Warning

Danger of accidentsಘReduced braking due to damaged brake discs.

ದ Always lay the wheel down in such a way that the brake disc is not damaged.

ದ Take the rear wheel out of the swing arm.

100145-10

Fitting rear wheelbx

Info

Do not operate the foot brake when the rear wheel is removed.

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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

Warning

Danger of accidentsಘNo braking effect when operating the rear brake.

ದ After installing the rear wheel, always operate the footbrake until the pressure point is reached.

ದ

Checking the rear hub rubber dampers.b

x ( P. 85)

MAINTENANCE WORK ON CHASSIS AND ENGINE 84

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Remove the bushingb

seal ringb

Long-life grease ( P. 155)

.

. Clean and grease the roll surfaces of the bushing and the shaft

100146-10

100147-10

ದ Clean and grease the thread of the wheel spindle and nutb

Long-life grease ( P. 155)

ದ Clean the fixing locations on the brake caliper support and swingarm.
ದ Mount the rubber damper and rear sprocket carrier in the rear wheel.
ದ Stand the rear wheel in the swingarm and mount the brake caliper on the brake disc.
ದ Push the brake caliper support and the swingarmb into the fixing location. Lay the

chain on the rear sprocket and fit the wheel spindle.

.

Info

Fit the chain left and right adjustersb in similar positions.

ದ Push the rear whell forwards so that the chain adjusters are located on the adjusting

screws, and tighten nutb
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 marksb

Nut, rear wheel spindle M25x1.5 90bNm (66.4blbfbft)

ದ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and

there is a tight spot.

ದ Taking rear from work stand. ( P. 57)

.

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 85

Checking the rear hub rubber dampersbx

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.

ದ

Remove the rear wheel.b

ದ Check the rubber dampers of the rear hub for damage and wear.

» If the rubber dampers of the rear hub are damaged or worn:

ದ Change all rubber dampers in the rear hub.

100148-10

ದ Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the

wheel spindle in the hub.

ದ To check the playb

Info

Measure the play on the outside of the rear sprocket.

x ( P. 82)

, hold the rear wheel tight and try to rotate the rear sprocket.

100149-10

Play in rubber dampers, rear wheel ืb5bmm (ืb0.2bin)

» If the playb

ದ Change all rubber dampers in the rear hub.

ದ

Fit the rear wheel.b

 is more than the specified value:

x ( P. 83)

MAINTENANCE WORK ON CHASSIS AND ENGINE 86

Tire condition checking

Warning

Danger of accidentsಘUncontrollable handling behavior caused by a flat tire.

ದ For your own safety, have damaged tires changed immediately.

Warning

Danger of crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.

ದ 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 accidentsಘUncontrollable handling behavior caused by non-approved tires/wheels.

ದ Use only tires/wheels approved by KTM with the corresponding speed index.

Warning

Danger of accidentsಘReduced road grip with new tires.

ದ 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.

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE 87

ದ Examine the tires for cuts, foreign bodies and other damage.
ದ Check the depth of the tread.

»

100172-10

Checking tire air pressure

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.

ದ Remove dust cap.
ದ Check tire air pressure when tires are cold.

Tire air pressure, road, solo

Tire air pressure with passenger / fully loaded

100170-10

» If the tire pressure does not meet specifications:

ದ Mount dust cap.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth: ุb2bmm (ุb0.08bin)
If the minimum tread depth is insufficient:

ದ Change the tires.

front 2.0bbar (29bpsi)
Rear 2.0bbar (29bpsi)

front 2.0bbar (29bpsi)
Rear 2.2bbar (32bpsi)

ದ Correct tire pressure.

MAINTENANCE WORK ON CHASSIS AND ENGINE 88

Checking spoke tension (690bSUPERMOTO)

Warning

Danger of accidentsಘUnstable riding behavior due to loose spokes.

ದ 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.

ದ To check spoke tension, tap each spoke with a screwdriver.

Specification

You should hear a high note.

Spoke nipple, front wheel M4,5 5bNm (3.7blbfbft)
Spoke nipple, rear wheel M5 5bNm (3.7blbfbft)

Info

100171-10

If you hear different tone frequencies from different spokes, this is an indication
of different spoke tensions.

MAINTENANCE WORK ON CHASSIS AND ENGINE 89

Removing the seat

ದ Insert the ignition key in the seat lockb and turn it 45° counterclockwise.
ದ Lift up the seat at the rear, pull it back and remove from above.

100108-10

Mounting the seat

ದ Suspend the seat on the screwb, press the rear downwards and at the same time push

it forwards. The two projectionsb

ದ Push the locking pinb

 into the lock housing and push the back of the seat down until

the locking pin locks in place with an audible click.

ದ Remove the ignition key from the seat lock.
ದ Finally, check that the seat is correctly mounted.

 must be inserted into the frame.

400155-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 90

Reinstalling the fuel tank

ದ Remove the seat. ( P. 89)
ದ Remove screwb.

Info

The fuel lines do not need to be disconnected.

100173-10

ದ Lay a clothb over the subframe and straighten the steering.
ದ Carefully raise the fuel tank and move it backwards.
ದ Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat-

ing tankb
spoiler to prevent damage.

100174-10

 (see illustration). Place a clothb between the compensating tank and the

MAINTENANCE WORK ON CHASSIS AND ENGINE 91

Positioning the fuel tank

ದ Remove the clothb from between the compensating tank and the spoiler.

100174-11

ದ Carefully move the fuel tank forwards and lower it.
ದ Mount and tighten the screwb

tank for tight fitting.
Specification

Screw, fuel tank bracket M8 15bNm (11.1blbfbft)

ದ Check the routing of the fuel hoses.
ದ Mount the seat. ( P. 89)

100175-10

 with the rubber bushing and bearing sleeve. Check fuel

MAINTENANCE WORK ON CHASSIS AND ENGINE 92

Removing the batterybx

Warning

Risk of injuryಘBattery acid and battery gases cause serious cauterization.

ದ Keep batteries out of the reach of children.
ದ Wear suitable protective clothing and goggles.
ದ Avoid contact with battery acid and battery gases.
ದ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ದ 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.

ದ Remove the seat. ( P. 89)
ದ Reinstall the fuel tank. ( P. 90)
ದ Disconnect the negative (minus) cable of the battery.

100169-10

ದ Detach and remove the rubber bandb
ದ Take off the positive terminal coverb
ದ Disconnect the positive (plus) cable of the battery.
ದ Pull the battery to the right out of the battery rack.

Info

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.

.

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 93

Installing the batterybx

ದ Push the battery from the right into the battery rack.

Info

The battery terminals must be at the front.

ದ Secure the battery with the rubber bandb

.

ದ Attach the positive cable and replace the positive terminal cover.
ದ Attach the minus cableb.

100169-11

ದ Position the fuel tank. ( P. 91)
ದ Mount the seat. ( P. 89)
ದ Set the clock. ( P. 28)

Recharging the batterybx

Warning

Risk of injuryಘBattery acid and battery gases cause serious cauterization.

ದ Keep batteries out of the reach of children.
ದ Wear suitable protective clothing and goggles.
ದ Avoid contact with battery acid and battery gases.
ದ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ದ 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 hazardಘComponents and battery acid are a danger to the environment.

ದ Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

MAINTENANCE WORK ON CHASSIS AND ENGINE 94

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

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 charge time are exceeded, electrolyte escapes through the breathing holes. The
battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

ದ Switch off all power-consuming components and switch off the engine.
ದ Reinstall the fuel tank. ( P. 90)
ದ Disconnect the minus (negative) cable of the battery to avoid damage to the motorcy-

cle's electronics.

MAINTENANCE WORK ON CHASSIS AND ENGINE 95

ದ Connect the battery charger to the battery. Switch on the battery charger.

Battery chargerb(58429074000)

You can also use the battery charger to test rest potential and start potential of the bat­tery, and to test the generator. With this device, you cannot overcharge the battery.

Info

Never remove the lidb.

Changing the main fuse

100151-10

Charge the battery according to the instructionsb

ದ Switch off the charger after charging. Disconnect the battery.

Specification

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the

motorcycle is not in use.

ದ Position the fuel tank. ( P. 91)
ದ Mount the seat. ( P. 89)
ದ Set the clock. ( P. 28)

3bmonths

 on the battery casing.

Warning

Fire hazardಘThe electrical system can be overloaded by the use of incorrect fuses.

ದ Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

MAINTENANCE WORK ON CHASSIS AND ENGINE 96

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.

ದ Switch off all power-consuming components and switch off the engine.
ದ Remove the seat. ( P. 89)
ದ Reinstall the fuel tank. ( P. 90)
ದ Remove the protection coverb.
ದ Remove a defective main fuseb
ದ Check parts for damage and wear. Replace damaged or worn parts.

Info

A reserve fuseb is located in the starter relay.

ದ Fit a new main fuse.

 with a needle nose plier.

100152-10

Fuseb(58011109130) ( P. 143)

Info

If the new fuse burns out, contact an authorized KTM workshop.

ದ Replace the protection cover.
ದ Position the fuel tank. ( P. 91)
ದ Mount the seat. ( P. 89)
ದ Set the clock. ( P. 28)

MAINTENANCE WORK ON CHASSIS AND ENGINE 97

Changing fuses of individual power consumers

Info

The fuse box containing the fuses of individual power consumers is located under the seat.

ದ Switch off all power-consuming components and switch off the engine.
ದ Remove the seat. ( P. 89)
ದ Open the fuse box coverb.

100153-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 98

ದ Remove defective fuse.

Specification

Fuseb1 - 10A - ignition, combination instrument, alarm system (optional)
Fuseb2 - 10A - clock, ignition (EFI control unit)
Fuseb3 - 10A - throttle valve control unit
Fuseb4 - 10A - fuel pump
Fuseb5 - 10A - radiator fan
Fuseb6 - 10A - horn, brake light, flasher light, alarm system (optional)
Fuseb7 - 15A - high beam, low beam, parking light, tail light, license plate lamp
Fuseb8 - 10A - for supplementary equipment (accessories connected with ignition

switch)
Fuseb9 - 10A - for supplementary equipment (standard accessories)
Fuseb10 - not used
FusebSPARE - 10A/15A - spare fuses

ದ Check parts for damage and wear. Replace damaged or worn parts.

100154-10

Info

A defective fuse is shown by a burned-out fuse wireb.