KTM 2014 690 SMC R EU Operating instructions

REPAIR MANUAL 2014
690 SMC R EU
690 SMC R AU/GB
Art. no. 3206193en

INTRODUCTION 1
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2014 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1 Repair Manual .................................................. 6
2.2 Safety advice.................................................... 6
2.3 Degrees of risk and symbols ............................... 6
2.4 Work rules........................................................ 6
3 IMPORTANT INFORMATION ......................................... 7
3.1 Guarantee, warranty .......................................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Figures ............................................................ 7
4 SERIAL NUMBERS ...................................................... 8
4.1 Chassis number ................................................ 8
4.2 Type label ........................................................ 8
4.3 Engine number ................................................. 8
4.4 Key number...................................................... 8
4.5 Fork part number .............................................. 8
4.6 Shock absorber part number .............................. 9
5 MOTORCYCLE ........................................................... 10
5.1 Raising the motorcycle with the rear wheel
stand ............................................................. 10
5.2 Taking the motorcycle off of the rear wheel
stand ............................................................. 10
5.3 Raising the motorcycle with the front wheel
stand ............................................................. 10
5.4 Taking the motorcycle off of the front wheel
stand ............................................................. 11
5.5 Raising the motorcycle with a lift stand............. 11
5.6 Removing the motorcycle from the lift stand...... 11
5.7 Raising the motorcycle with the work stand ....... 11
5.8 Removing the motorcycle from the work stand ... 12
5.9 Starting.......................................................... 12
5.10 Starting the motorcycle to make checks ............ 13
6 FORK, TRIPLE CLAMP ............................................... 14
6.1 Adjusting the compression damping of the
fork ............................................................... 14
6.2 Adjusting the rebound damping of the fork ........ 14
6.3 Bleeding the fork legs...................................... 15
6.4 Cleaning the dust boots of the fork legs............. 15
6.5 Removing the fork protector ............................. 15
6.6 Installing the fork protector.............................. 16
6.7 Removing fork legs.......................................... 16
6.8 Installing the fork legs..................................... 17
6.9 Disassembling the fork legs.............................. 18
6.10 Checking the fork legs ..................................... 21
6.11 Assembling the fork legs.................................. 22
6.12 Checking the steering head bearing play............ 26
6.13 Adjusting the steering head bearing play ........... 26
7 HANDLEBAR, CONTROLS........................................... 28
7.1 Handlebar position.......................................... 28
7.2 Adjusting the handlebar position ...................... 28
7.3 Changing the throttle grip ................................ 28
8 SHOCK ABSORBER, SWINGARM ................................ 33
8.1 Adjusting the high-speed compression
damping of the shock absorber......................... 33
8.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 33
8.3 Adjusting the rebound damping of the shock
absorber......................................................... 34
8.4 Measuring the unloaded rear wheel sag ............. 34
8.5 Checking the static sag of the shock absorber.... 34
8.6 Checking the riding sag of the shock absorber.... 35
8.7 Adjusting the spring preload of the shock
absorber......................................................... 35
8.8 Adjusting the riding sag................................... 36
8.9 Removing the shock absorber........................... 36
8.10 Installing the shock absorber............................ 37
8.11 Servicing the shock absorber............................ 39
8.12 Removing the spring........................................ 39
8.13 Dismantling the damper .................................. 40
8.14 Disassembling the piston rod ........................... 41
8.15 Checking the damper ...................................... 42
8.16 Removing the heim joint.................................. 43
8.17 Installing the heim joint................................... 44
8.18 Assembling the piston rod................................ 45
8.19 Assembling the damper ................................... 46
8.20 Bleeding and filling the damper ....................... 48
8.21 Filling the damper with nitrogen....................... 50
8.22 Installing the spring ........................................ 51
9 EXHAUST.................................................................. 53
9.1 Removing the manifold.................................... 53
9.2 Installing the manifold .................................... 54
9.3 Removing the main silencer ............................. 55
9.4 Installing the main silencer.............................. 56
10 AIR FILTER ............................................................... 57
10.1 Removing the air filter..................................... 57
10.2 Installing the air filter...................................... 57
10.3 Removing the air filter box ............................... 57
10.4 Installing the air filter box................................ 59
11 FUEL TANK, SEAT, TRIM ........................................... 61
11.1 Opening the filler cap...................................... 61
11.2 Closing filler cap............................................. 61
11.3 Removing the seat .......................................... 61
11.4 Mounting the seat........................................... 62
11.5 Taking off the side cover.................................. 62
11.6 Mounting the side cover................................... 62
11.7 Checking the fuel pressure............................... 62
11.8 Changing the fuel filter.................................... 64
11.9 Changing the fuel pump .................................. 67
12 WHEELS ................................................................... 70
12.1 Checking the tire air pressure........................... 70
12.2 Checking the tire condition .............................. 70
12.3 Checking the brake discs ................................. 71
12.4 Checking the spoke tension.............................. 71
12.5 Checking the rim run-out ................................. 72
12.6 Front wheel .................................................... 72
12.6.1 Removing front wheel.................................. 72
12.6.2 Installing the front wheel............................. 73
12.6.3 Removing the brake disc of the front brake.... 74
12.6.4 Installing the brake disc of the front brake .... 74
12.7 Rear wheel ..................................................... 74
12.7.1 Removing rear wheel ................................... 74
12.7.2 Installing the rear wheel .............................. 75
12.7.3 Removing the brake disc of the rear brake..... 76
12.7.4 Installing the brake disc of the rear brake...... 76
12.7.5 Checking the chain tension.......................... 77
12.7.6 Adjusting the chain tension ......................... 77
12.7.7 Adjusting chain guide.................................. 78
12.7.8 Checking the chain, rear sprocket, engine
sprocket, and chain guide............................ 78
12.7.9 Cleaning the chain...................................... 80
12.7.10 Checking the rear hub rubber dampers.......... 80

TABLE OF CONTENTS 3
13 WIRING HARNESS, BATTERY..................................... 82
13.1 Removing the battery ...................................... 82
13.2 Installing the battery ....................................... 82
13.3 Disconnecting the battery ................................ 83
13.4 Connecting the battery .................................... 83
13.5 Recharging the battery .................................... 83
13.6 Checking the charging voltage.......................... 84
13.7 Checking the quiescent current ........................ 85
13.8 Changing the main fuse................................... 85
13.9 Changing fuses of individual power
consumers...................................................... 86
13.10 Adjusting the engine characteristic ................... 87
14 BRAKE SYSTEM ........................................................ 89
14.1 Checking the front brake linings ....................... 89
14.2 Changing the brake linings of the front brake..... 89
14.3 Adjusting the basic position of the hand brake
lever .............................................................. 90
14.4 Checking brake fluid level of front brake ........... 90
14.5 Adding front brake fluid................................... 91
14.6 Changing the front brake fluid.......................... 92
14.7 Checking the rear brake linings ........................ 93
14.8 Changing the rear brake linings ........................ 93
14.9 Checking the free travel of foot brake lever ........ 95
14.10 Adjusting the basic position of the foot brake
lever .............................................................. 95
14.11 Checking rear brake fluid level ......................... 95
14.12 Adding rear brake fluid.................................... 96
14.13 Changing the rear brake fluid ........................... 97
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 99
15.1 Combination instrument .................................. 99
15.1.1 Setting kilometers or miles .......................... 99
15.1.2 Setting the clock ........................................ 99
15.1.3 Setting/resetting display TRIP 1 ................... 99
15.1.4 Setting/resetting display TRIP 2 ................... 99
15.1.5 Setting the wheel circumference ................ 100
15.2 Checking the headlight setting ....................... 101
15.3 Adjusting the headlight range......................... 101
15.4 Removing the headlight mask with the
headlight...................................................... 101
15.5 Installing the headlight mask with the
headlight...................................................... 102
15.6 Changing the parking light bulb...................... 102
15.7 Changing the headlight bulb .......................... 103
15.8 Changing the turn signal bulb ........................ 104
16 ENGINE .................................................................. 105
16.1 Removing the engine..................................... 105
16.2 Installing the engine...................................... 107
16.3 Disassembling the engine .............................. 111
16.3.1 Clamping the engine into the engine
assembly stand......................................... 111
16.3.2 Draining the engine oil .............................. 111
16.3.3 Removing the starter motor........................ 112
16.3.4 Removing the valve cover........................... 112
16.3.5 Removing the alternator cover .................... 112
16.3.6 Removing the spacer................................. 112
16.3.7 Removing the gear position sensor.............. 113
16.3.8 Removing the oil filter............................... 113
16.3.9 Removing the thermostat........................... 113
16.3.10 Setting engine to ignition top dead center ... 113
16.3.11 Removing the spark plugs.......................... 114
16.3.12 Removing the timing chain tensioner .......... 114
16.3.13 Removing the camshafts............................ 114
16.3.14 Removing the cylinder head....................... 115
16.3.15 Removing the piston ................................. 115
16.3.16 Removing the water pump impeller............. 116
16.3.17 Removing the rotor.................................... 116
16.3.18 Removing the timing chain rails ................. 117
16.3.19 Removing the timing chain and timing
chain sprocket.......................................... 117
16.3.20 Removing the ignition pulse generator ........ 118
16.3.21 Removing the clutch cover......................... 118
16.3.22 Removing the spacer and spring................. 118
16.3.23 Removing the clutch basket....................... 119
16.3.24 Removing the primary gear ........................ 120
16.3.25 Removing the starter drive ......................... 120
16.3.26 Removing shift shaft ................................. 121
16.3.27 Removing shift drum locating..................... 121
16.3.28 Removing locking lever.............................. 122
16.3.29 Removing the oil pumps ............................ 122
16.3.30 Removing the left engine case.................... 123
16.3.31 Removing the crankshaft and balancer
shaft........................................................ 124
16.3.32 Removing the transmission shafts............... 124
16.4 Work on individual parts ................................ 125
16.4.1 Work on the right section of the engine
case ........................................................ 125
16.4.2 Work on the left section of the engine
case ........................................................ 126
16.4.3 Work on the clutch cover ........................... 128
16.4.4 Removing crankshaft bearing inner ring ...... 128
16.4.5 Removing balancer shaft drive wheel .......... 128
16.4.6 Changing the connecting rod, conrod
bearing, and crank pin .............................. 128
16.4.7 Checking crankshaft run-out at bearing
pin .......................................................... 130
16.4.8 Installing balancer shaft drive wheel........... 130
16.4.9 Installing crankshaft bearing inner ring ....... 131
16.4.10 Measuring axial clearance of crankshaft
and balancer shaft .................................... 131
16.4.11 Cylinder - Nikasil®coating ......................... 132
16.4.12 Checking/measuring the cylinder ................ 132
16.4.13 Checking/measuring the piston................... 133
16.4.14 Checking piston ring end gap ..................... 134
16.4.15 Determining the piston/cylinder mounting
clearance ................................................. 134
16.4.16 Checking the oil pumps for wear................. 134
16.4.17 Replacing autodecompressor...................... 135
16.4.18 Preparing timing chain tensioner for
installation............................................... 136
16.4.19 Checking the timing assembly.................... 137
16.4.20 Removing the rocker arm........................... 138
16.4.21 Changing the camshaft bearing .................. 138
16.4.22 Removing the valves.................................. 139
16.4.23 Checking the valves .................................. 140
16.4.24 Checking valve springs .............................. 140
16.4.25 Checking valve spring retainer.................... 140
16.4.26 Checking the cylinder head........................ 140
16.4.27 Installing the valves .................................. 141
16.4.28 Installing the rocker arm............................ 142
16.4.29 Disassembling the antihopping clutch......... 142
16.4.30 Checking the clutch .................................. 143
16.4.31 Preassembling the antihopping clutch......... 144
16.4.32 Checking the shift mechanism ................... 145
16.4.33 Preassembling the shift shaft..................... 146
16.4.34 Disassembling the main shaft .................... 147

TABLE OF CONTENTS 4
16.4.35 Disassembling the countershaft.................. 148
16.4.36 Checking the transmission ......................... 148
16.4.37 Assembling the main shaft......................... 150
16.4.38 Assembling the countershaft...................... 151
16.4.39 Checking the starter drive .......................... 152
16.4.40 Checking freewheel................................... 153
16.4.41 Removing freewheel .................................. 153
16.4.42 Installing freewheel................................... 153
16.5 Assembling the engine .................................. 154
16.5.1 Installing the transmission shafts ............... 154
16.5.2 Installing crankshaft and balancer shaft...... 155
16.5.3 Installing the left engine case .................... 156
16.5.4 Installing the oil pumps............................. 157
16.5.5 Installing locking lever .............................. 158
16.5.6 Installing shift drum locating ..................... 158
16.5.7 Installing shift shaft.................................. 158
16.5.8 Installing the starter drive.......................... 158
16.5.9 Installing the primary gear ......................... 159
16.5.10 Installing the clutch basket........................ 159
16.5.11 Installing the spacer and spring.................. 161
16.5.12 Installing the clutch cover ......................... 161
16.5.13 Installing the ignition pulse generator ......... 162
16.5.14 Installing timing chain and timing chain
sprocket................................................... 162
16.5.15 Installing the timing chain rails.................. 162
16.5.16 Installing the rotor .................................... 163
16.5.17 Adjusting crankshaft position sensor
distance................................................... 163
16.5.18 Setting engine to top dead center............... 164
16.5.19 Mounting the water pump cover ................. 164
16.5.20 Installing piston........................................ 164
16.5.21 Installing the cylinder head........................ 166
16.5.22 Installing the camshafts ............................ 167
16.5.23 Installing timing chain tensioner ................ 167
16.5.24 Checking valve clearance........................... 168
16.5.25 Adjusting the valve clearance..................... 169
16.5.26 Installing the spark plugs........................... 170
16.5.27 Installing the thermostat............................ 170
16.5.28 Installing the oil filter................................ 170
16.5.29 Installing the gear position sensor .............. 171
16.5.30 Installing the spacer.................................. 171
16.5.31 Installing the alternator cover..................... 171
16.5.32 Installing oil screens ................................. 172
16.5.33 Installing the starter motor......................... 172
16.5.34 Installing the valve cover ........................... 173
16.5.35 Removing the engine from the engine
assembly stand......................................... 173
17 CLUTCH.................................................................. 174
17.1 Checking/rectifying the fluid level of the
hydraulic clutch............................................ 174
17.2 Changing the hydraulic clutch fluid ................ 174
18 SHIFT MECHANISM................................................. 175
18.1 Changing the gear position sensor................... 175
18.2 Programming the gear position sensor............. 177
19 WATER PUMP, COOLING SYSTEM ............................ 178
19.1 Draining the coolant...................................... 178
19.2 Filling/bleeding the cooling system ................. 178
19.3 Checking the antifreeze and coolant level........ 179
19.4 Checking the coolant level ............................. 180
20 LUBRICATION SYSTEM............................................ 181
20.1 Oil circuit..................................................... 181
20.2 Checking the engine oil level.......................... 181
20.3 Checking the engine oil pressure .................... 182
20.4 Changing the engine oil and filter, cleaning
the oil screens .............................................. 183
20.5 Draining the engine oil .................................. 183
20.6 Removing the oil filter ................................... 184
20.7 Installing the oil filter.................................... 184
20.8 Cleaning the oil screens................................. 185
20.9 Filling up with engine oil ............................... 186
20.10 Adding engine oil.......................................... 186
21 IGNITION ................................................................ 187
21.1 Alternator - checking the stator winding .......... 187
21.2 Checking the spark plug connector ................. 187
21.3 Ignition coil –checking the secondary
winding........................................................ 188
22 THROTTLE VALVE BODY .......................................... 189
22.1 Performing the initialization run ..................... 189
23 TECHNICAL DATA.................................................... 190
23.1 Engine ......................................................... 190
23.2 Engine tolerance, wear limits ......................... 190
23.3 Engine tightening torques .............................. 192
23.4 Capacities .................................................... 193
23.4.1 Engine oil ................................................ 193
23.4.2 Coolant .................................................... 193
23.4.3 Fuel ........................................................ 193
23.5 Chassis ........................................................ 194
23.6 Electrical system........................................... 194
23.7 Tires............................................................ 195
23.8 Fork............................................................. 195
23.9 Shock absorber............................................. 195
23.10 Chassis tightening torques ............................. 196
24 CLEANING/PROTECTIVE TREATMENT....................... 198
24.1 Cleaning the motorcycle ................................ 198
24.2 Checks and maintenance steps for winter
operation...................................................... 199
25 STORAGE................................................................ 200
25.1 Storage ........................................................ 200
25.2 Preparing for use after storage........................ 200
26 SERVICE SCHEDULE ............................................... 201
26.1 Service schedule........................................... 201
27 WIRING DIAGRAM ................................................... 202
27.1 Page 01 of 11 .............................................. 202
27.2 Page 02 of 11 .............................................. 204
27.3 Page 03 of 11 .............................................. 206
27.4 Page 04 of 11 .............................................. 208
27.5 Page 05 of 11 .............................................. 210
27.6 Page 06 of 11 .............................................. 212
27.7 Page 07 of 11 .............................................. 214
27.8 Page 08 of 11 .............................................. 216
27.9 Page 09 of 11 .............................................. 218
27.10 Page 10 of 11 .............................................. 220
27.11 Page 11 of 11 .............................................. 222
28 SUBSTANCES ......................................................... 224
29 AUXILIARY SUBSTANCES ........................................ 226
30 SPECIAL TOOLS ...................................................... 228
31 STANDARDS ........................................................... 241
INDEX ............................................................................ 242

1 MEANS OF REPRESENTATION 5
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SAFETY ADVICE 6
2.1 Repair Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.

3 IMPORTANT INFORMATION 7
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-
ered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3 Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.

4 SERIAL NUMBERS 8
4.1 Chassis number
401945-10
The chassis number is stamped on the steering head on the right.
4.2 Type label
101973-10
The type label is located on the right side of the frame.
4.3 Engine number
401949-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.4 Key number
100179-10
The key number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
4.5 Fork part number
401947-10
The fork part number is stamped on the inner side of the fork stub.

4 SERIAL NUMBERS 9
4.6 Shock absorber part number
402025-10
The shock absorber part number is on the left of the shock absorber.

5 MOTORCYCLE 10
5.1 Raising the motorcycle with the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
101984-10
–Insert the adapter into the rear wheel stand and screw into the swingarm on both
sides.
Adapter (61029055110) ( p. 231)
Rear wheel stand (61029055400) ( p. 231)
–Position the motorcycle upright, align the stand and raise the motorcycle.
5.2 Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
401943-10
–Secure the motorcycle against falling over.
–Remove the rear wheel stand and lean the vehicle on the side stand.
5.3 Raising the motorcycle with the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
Preparatory work
–Raise the motorcycle with the rear wheel stand. ( p. 10)
101985-01
Main work
–Move the handlebar to the straight-ahead position. Align the front wheel stand with
the fork legs using the adapters.
Front wheel stand (61029055300) ( p. 231)
Info
Always raise the rear of the motorcycle first.
–Raise the front of the motorcycle.

5 MOTORCYCLE 11
5.4 Taking the motorcycle off of the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Secure the motorcycle against falling over.
–Remove the front wheel stand.
5.5 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
401942-01
–Stand the motorcycle upright on a level surface.
–Raise the motorcycle in the area of the footrest bracket.
–Secure the motorcycle against falling over.
5.6 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
401943-10
–Remove the motorcycle from the lift stand and rest it on its side stand.
–Remove the lift stand.
5.7 Raising the motorcycle with the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
300579-10
–Mount the special tool on the footrest.
Work stand adapter (75029036000) ( p. 234)

5 MOTORCYCLE 12
300201-10
–Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 232)
5.8 Removing the motorcycle from the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
300201-10
–Secure the motorcycle against falling over.
–Remove the work stand and lean the vehicle on the side stand.
300579-10
–Remove the special tool.
5.9 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.

5 MOTORCYCLE 13
B00782-10
–Turn the emergency OFF switch to the position .
–Switch on the ignition by turning the ignition key to position ON .
After you switch on the ignition, you can hear the fuel pump working for about
two seconds. The function check of the combination instrument is run at the
same time.
The ABS warning lamp lights up and goes back out after starting off.
–Shift gear to neutral.
The green idling speed indicator lamp Nlights up.
–Press the electric starter button .
Info
Do not press the electric starter button until the combination instrument
function check is finished.
When starting, DO NOT open the throttle. If you open the throttle during the
starting procedure, fuel is not injected by the engine management system
and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds
before trying again.
This motorcycle is equipped with a safety starting system. You can only start
the engine if the transmission is in neutral or if the clutch lever is pulled
when a gear is engaged. If the side stand is folded out and you shift into
gear and release the clutch lever, the engine stops.
–Take the weight off the side stand and swing it back up with your foot as far as it
will go.
401426-11
Switching off ABS
KTM recommends riding with ABS at all times. However, situations may arise in
which ABS is not advantageous.
Condition
Vehicle stationary, engine running.
–Press the button for 3 - 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
5.10 Starting the motorcycle to make checks
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
B00782-10
–Turn the emergency OFF switch to the position .
–Shift gear to neutral.
–Switch on the ignition.
–Press the electric starter button .
Info
Do not open the throttle.

6 FORK, TRIPLE CLAMP 14
6.1 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
101981-10
–Turn the white adjusting screw all the way clockwise.
Info
Adjusting screw is located at the upper end of the left fork leg.
The compression damping is located in the left fork leg COMP (white adjust-
ing screw). The rebound damping is located in the right fork leg REB (red
adjusting screw).
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
6.2 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork rebound behavior.
101982-10
–Turn the red adjusting screw all the way clockwise.
Info
Adjusting screw is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg REB (red adjusting
screw). The compression damping is located in the left fork leg COMP (white
adjusting screw).
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

6 FORK, TRIPLE CLAMP 15
6.3 Bleeding the fork legs
Preparatory work
–Lean the motorcycle on the side stand.
601879-10
Main work
–Loosen bleeder screw .
Any excess pressure escapes from the interior of the fork.
–Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.
6.4 Cleaning the dust boots of the fork legs
Preparatory work
–Raise the motorcycle with a lift stand. ( p. 11)
–Remove the fork protector. ( p. 15)
L00350-10
Main work
–Push dust boots on both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind the dust boots can start to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–Clean and oil the dust boots and inside fork tube of both fork legs.
Universal oil spray ( p. 227)
–Push the dust boots back into their normal position.
–Remove excess oil.
Finishing work
–Install the fork protector. ( p. 16)
–Remove the motorcycle from the lift stand. ( p. 11)
6.5 Removing the fork protector
101986-10
–Remove screws and take off clamp.
–Remove screws on left fork leg. Remove the fork protector.
–Remove the screws on the right fork leg. Remove the fork protector.

6 FORK, TRIPLE CLAMP 16
6.6 Installing the fork protector
101986-11
–Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the brake line and cable harness. Put the clamp on, mount and tighten
screws .
–Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
6.7 Removing fork legs
Preparatory work
–Raise the motorcycle with the work stand. ( p. 11)
–Tie the rear of the vehicle down.
101995-10
Main work
–Remove screw and pull wheel speed sensor out of the hole.
–Remove screws and spacers .
–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.
G00827-10
–Loosen screw and screws .
–Unscrew screw about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking effect caused by damaged brake
discs.
–Always lay the wheel down in such a way that the brake discs are not
damaged.
–Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
G00828-10
–Remove screws and the clamp. Take the brake line and wiring harness out of
the holder.
G00832-10
–Remove screws . Take off the fork protector.

6 FORK, TRIPLE CLAMP 17
G00829-10
–Loosen the screws of the triple clamp. Remove the fork legs from the bottom.
6.8 Installing the fork legs
G00829-11
–Slide the fork legs into the triple clamps on both sides.
Info
The bleeder screws must face forwards.
The topmost milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
The upper fork projection must be the same on both sides.
–Tighten screws on both sides.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
G00832-11
–Position the fork protection. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
G00828-11
–Position the brake line, wiring harness and clamp.
–Mount and tighten screws .
G00830-11
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–Clean screw and the wheel spindle.
–Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
–Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)

6 FORK, TRIPLE CLAMP 18
G00831-10
–Position the brake caliper and check that the brake linings are seated correctly.
–Mount screws with spacers but do not tighten.
–Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point. Fix the hand brake lever in the activated position.
The brake caliper straightens.
–Tighten screws .
Guideline
Screw, front brake caliper M10x1.25 45 Nm
(33.2 lbf ft)
Loctite®243™
–Remove the fixation of the hand brake lever.
–Unload the rear of the vehicle.
–Remove the motorcycle from the work stand. ( p. 12)
G00827-11
–Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
6.9 Disassembling the fork legs
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.
202305-10
–Note down the current state of the rebound and compression damping .
–Note down the current spring preload .
–Completely open the adjusters of the rebound damping, compression damping, and
spring preload.
202307-10
–Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 240)
–Remove adjuster .
202308-10
–Release Preload Adjuster .
Pin wrench (T103) ( p. 237)
Info
The Preload Adjuster cannot be removed yet.