KTM 790 Adventure R 2019 Operating instructions

REPAIR MANUAL 2019
790 Adventure R
Art. no. 3206373en

INT R ODUCTION
Read this repair manual carefully and t ho rou ghly before beginning work.
Th e vehicle will only be ab le to meet the demands pl aced on it if the spec ified se rvi ce work is performed r eg ul arly
and properly.
This repair manual wa s written to correspond to•the latest st ate of th is model ser i es. We reserve the right to ma ke
changes in the in terest of technical advancement without updating this repair manual at the same ti me .
We shall no t provi de a descripti on of general workshop methods. Likewi se, sa fety ru l es that apply in a workshop
are no t specified here. It is assumed that the repair work wi ll be perfor med by a ful ly trained mechanic.
Al l specifications co ntained herein are n on -b in ding. K TM Sportmotorcycle GmbH specifical ly re se rv es the right
to mod i fy or delete t ech ni ca l specifications, pr ices, co lor s, forms, materials, services, des igns, eq uipment, etc.,
without pr i or notice and witho ut specifying reasons, to adapt these to l oca l co nditi ons, as we lI as to stop produc-
tion of a particul ar model wi thout pri or notice. KTM accepts no liability for delivery options, dev iatio ns from fig-
ure s and descriptions, misprints, and other e rr ors. The models po rt rayed partly contain speci al equipment that
does not belong to the r egu l ar scope of supply.
© 20 19 KT M Sportmotorcycle GmbH, Mattighofen Austr ia
Al l rights reserved
Reproduction, even in part, as well as copying of al l kin ds, is permitted only with the express written permissi on
of the co pyright owner.
KTM appli es quality assurance processes that lead to the highest possible pr od u ct quality as
def in ed in the ISO 9001 in ternat,ional q ua lity management standard.
e I
SO 9001(12 100 6061)
Issued by : TOV Management Service
R£ G NO , 12 1 00 6061
KTM Spo rtmotorcycle GmbH
Stallhof ners t raf3e 3
5230 Mattighofen, Austria
This document is valid fo r the following mo dels:
790 Adventure R EU (F9603S3)
790 Adventure R US (F9675S3)
I 1111111111111111 111 1 1111111 1 11111111111111111111111111
3206373en
02/2019

TABLE OF CONTENTS
1 MEANS
OF REPRESENTATION ...................... 8
1.1 Symbols used . .. ........ .. . .. .............. .. .... 8
1. 2 Fo rmats used... .. . .. .. .. .. .. ............... .. .. .. 8
2
SAFETY ADVICE........................................ .. .. 9
2.1 Repair Manual .... .. ........ .. ..... .. ............ 9
2.2 Safety advice.................. .. . .. .. ............ 9
2.3 Deg rees of risk a nd symbols................ 9
2.4 Work r ul es .................. .. ..................... 9
3 I
MPOR TANT NO T ES ....................................
10
3.1 Manufacturer and impl i ed warranty.... 10
3.2 Fue l, aux ilia ry substances............. .. ..
10
3.3 Spare parts, accessories . .. ......... .. ..... 10
3.4
Figur es .................. .. .......................
10
4 SER IA L NUMBERS .. .. .................................
11
4.1 V eh icle identificati on number............ 11
4.2 Type la bel ....... .. ......... .. ...................
11
4.3
Key number................................... ..
12
4.4 Engi ne number ................................
12
4.5 Fork part numb er .. .. .. ......... .. ....... .. ... 12
4.6 Shock absorber article number..... .. . .. 12
4.7 Steering damper article number .. ...... 13
5
MOTORCYCLE .......................................... ..
14
5.1 Li ftin g the mo torcycle with the front
l ift ing gea r ....... .. ....... .... ................ .. 14
5.2 Takililg the motorcycle o ff the front
l ifting gea r .. .. .... .. ................ .. . .. ..... .. 14
5.3 Raising t he motorcycle with rear
l ifting gear .................................. ....
15
5.4
Removing the rear of the motorcycle
fr om the Ii fti ng gear .. .. . .. .................. 15
5.5 Raising the motorcycle at the r
ear
using the work stand ........................
15
5.6 Removing the motorcycle from th e
work stand at the rear .... .... ...............
16
5.7 Raising the motorcycle at t
he front
using the work stand ....... .. ............. .. 16
5.8 Removing the motorcycle from the
work stand at the fr ont .....................
17
5.9 Starti ng the vehicle........ .. .. .. . .. . .. ...... 18
5.10 Starti ng the motorcycle to check the
f un ct i on ................... .. ..................... 19
6 FORK, TRIPLE CLAMP ........................... .. ... 20
6.1
Clea ning the dust boots of the fo rk
l egs ................................................
20
6.2 Adjusting the compressi on dampi ng
of the fork .......................................
20
6.3
Adjusting the rebound dampi ng of
the fork. .. . .. ,................. .. ................. 21
6 .4 Adjusting the spr in g pretension of
the fork................ .. ...... .. ................. 21
2
7
6.5
6.6
6.7
6.8
Removing fork protector.................... 22
Instal Ii ng the fork protector............. .. 23
Removing the fork legs .. . .. . .. ..... .. ...... 23
Installing t he fork legs .. .. ............... .. . 25
6.9 Serv ic in g the fork............................. 27
6.1O Disassembling the fork l egs .. ............. 28
6.11 Disassembling the ca rtridge ............ .. 31
6.12
6. 13
6. 14
Disassembling t he tap compression ... 34
Check in g the fork l egs .. .................... 35
Assembling the tap compression ....... 36
6. 15 Assembli ng the ca rtridge .................. 37
6.16 Ass em bli ng the fork l egs ................... 41
6.17 Checking the steeri ng h ead bearing
play .. .... .... ..................... .... ............. 46
6. 18 Ad justing the steering head bea ri ng
play ........ .. .. .................................... 46
6. 19 Lubricati ng the steering head
bear i ng ............... .. .......................... 48
6.20 Removing the lower triple clamp .. .... .. 48
6.2 1 Installing t he lower tr iple clamp ........ 50
6. 22 Cha ng in g the steeri ng h ead bea ri ng . .. 54
6.23 Cha ngi ng the st ee ring damper........... 56
HAN DLEBAR, CONTRO LS ................... ......... 57
7.1 Ad just in g the basic positi on of the
clutch lever .............................. .. ..... 57
7.2 Checking the free travel of the
clutch l ever ..................................... 57
7.3 Setti ng the free tr ave l of the clutch
lever ............................................... 58
7.4 Ad justing the tiandlebar position ....... 58
7.5 Cha ng in g t he throttle grip ................. 59
8 FRA ME ....................................... .. .. .. ......... 62
8.1 Che ck in g the frame ............. .. ........... 62
9 SHOCK ABSORBER, LINK FOR K...... .. .......... 63
9.1 Ad justing t he low-speed
compressi on dampi ng of the shock
abso r be r.......................................... 63
9.2 Adjusting t he tiigh-speed
compressi on damping of the shock
c:1l>surl>er .. ........................................ 63
9.3 Ad just in g the rebound damping of
the shock absor be r........................... 64
9.4 Adjusti ng the spring pre l oad of the
shock absorber .. ................... .. ......... 65
9.5 Check in g the heim joint for play .. ...... 65
9.6 Removing the shock absorber ....... .. . .. 66
9.7 In stalling the shock absorber............. 68
9.8 Changing the heim joint.................... 70
9.9 Serv ic in g the shock absorber........... .. 72
9. 10 Removing the spri ng .... .. ........ .. .... .. . .. 73
9.11 Disassembling the damper ................ 7 '1
9.12 Disassembling the piston rod ............ 75

TABLE OF CONTENTS
9. 13 Disa sse mb li ng the rebound 13. 11 Removing left fuel tank cover .......... 136
adjuster ....... .. ...... .. ......................... 77 13.12 Installing the left fuel tank cover ..... 136
9 .1 4 Checki
ng the damper .................. ..... 78
13 .13 Removing ri ght fuel tank cover ........ 137
9.15
Removing the heim joint................... 79 13.14
In stalling the right f uel tank cover ... 137
9.16 Installing the heim joint....................
80
13.15 Removing engine
gua rd .. ................ 138
9.17 Assembling the rebound adjuster
.. ..... 80
13.16 In stalling the eng in e gua rd ............. 138
9 .1 8 As se mbl in g t he piston rod ...... . .. ........ 81 13.17 Removing the front fen
de r .............. 1 40
9.19
Assembling the damper ....................
83
13.18 Installi ng the front fender ............... 140
9.20 Bleeding and fill ing the damper ........
85
13. 19
Removing the windshield ................ 141
9.21 Filling damper with nit roge n .............
88
13 .20 Installing the windshield................. 141
9.22 Installing the spri ng .. .......................
89
9.23 Checking the link fork ....... .. ............. 90
14 WHEELS .......... .. ...................................... 1 42
9.24 Checki ng the fork bea ri ng for play . .... 90 14.1 Ch
ec king tire pressure .. ............ ...... 142
9. 25 Re mov ing the link fork.. .. ..... .. .... .. ..... 91 14.2 Ch
ec king the tire condition ............. 142
9.26 Changi
ng the link fork bearing........... 93 14.3 Checking t
he rim run-out ........... .... . 143
9.27 Installing the link fork ....... .. ............. 97
14 .4 Checking the
wh eel bearing for
10 E XHAU ST S YS TE M ........ .. ......................... 100 pl
ay .. ............. .. .............................
144
14.5 Tubeless ti re system ............... .. ...... 145
10 .1
Removing the main si l en cer . .. . .. . .. ... 100
14 .6 Checking spo
ke tension ....... .. ..... .. .. 145
10.2 Installing the main silencer
.. ..... .. .. ..
100
14 .7
Che c ki ng brake discs............... .. ..... 146
10.3 Removing the exhaust syst
em ... .... ... 101 14.8 Programmi ng the tire pressure
1 0.4 Installing the e xh aust system .. .. ...... 103 sens
or (Option: With TP M S) .. .......... 146
14.9
Fro nt wheel ................................... 147
11 AIR FIL TER ...................................... .. ...... 1 09
14.9.l Remov i ng the front wheel .. ......... 147
11.1 Removing the air filter .. ....... .. ......... 109 14.9.2 lnstalli
ng the front wh ee l............ 148
11.2 Installi
ng the air fi lter..................... 110
14 .9.3 Changi ng the front wh ee I
11.3 Changing the air
fi lter, cleaning th,e bearing ..................................... 1
49
air filter box ................................... 111 14.9.4 Changing the front brake discs .... 151
12 FUEL
TA NK , SEAT, TRIM .......................... 113
14 .9.5 Changi ng the front t ube less
sealing pro file........ .. ........... ....... 152
12.1 Opening t he fuel tank fill er cap ....... 113
14 .9.6 Changing the front ti re pressure
12.2 Cl os in g the fuel tank filler cap ......... 113 sensor (Opti
on : With TPMS) .. ...... 155
12.3 Remo
vi ng the sea t ....................... .. 114
14.10 Rear wh eel ..... .. ............................. 156
12.4
Mounting the seat.................... .. .... 114
14 .10 .1 Remov i ng the rear whee I ............ 156
12.5 Re mov ing the fuel tank................... 114 14.10.2 Installing the
re ar whee l ............. 157
12.6 Installing the fuel tank .............. .. ... 117 14.10.3
Remov i ng the rear wh ee I (work
12.7 Checking th e fuel pressure.............. 119 stand,
fr ont) .. ....... .. ...... .. ...........
158
12.8 Changing the fuel level
se nsor ......... 122 14.10.4 I
ns talli ng the rear whee l (wo rk
12.9 Changing the fuel pump ......
.. . .. . .. ...
123
stand, front) .. ................. .. ..... .. .. 159
14 .10.5
Remov i ng the rear whee I (work
12.10
Changing the fuel fil ter................... 124 stand, r
ea r) ...................... .. ....... 161
12.11 Refueling ... .. .. .. ..... .. ...................... 129
14 .10.6 lnstalIi ng the re ar whee l (work
13 MASK , FE NDER , D EC AL .... .. ...................... 1 30
stand, rear) ............ .. ............... ..
162
14.10.7 Ch anging the re ar whee l
13.1 Re
mov ing the left s id e cov er ...........
130
bea ri ng . .. .................................. 163
13.2 Installing the left side co ver............ 130
14. 10.8 Changi ng the bea ri ng of the rear
13.3 Removi ng the r ig ht side cove r ......... 130 sprocket carrier.......
.... ............... 165
13.4 Installing the ri gh t s id e co ver .......... 131
14.10.9 Changing the r ea r brake di sc ....... 166
13.5 Removing the battery cov
er ............. 131
14.10 .10 Changi ngtherea rtubel ess
13.6 Installing the batte ry cover .. .... .. ...... 132 sealing profile............................ 167
13.7 Remov ing left fu el tank spoiler .. ...... 132 14.10.
11 Changi ng the re ar ti re pressure
13.8 Installing the left fuel tank spoiler ... 133
se nsor (Option: With TP M S) ........ 170
1 3.9 R em ov ing right fuel tank spo il er ...... 134
14 .10.12 Checking the chain tension ......... 171
13.10
Installing the right fuel tank
14. 10.13 Ad justing the chain tension .. ...... 172
spoiler .......................................... 135
3

TABLE OF CONTENTS
14 .10. 14 Checki ng the chain, rear 17.4 Changing the turn signal bulb
sprocket, engine sp ro cket, and
(US} .............................................
21 0
chain g ui de ............................... 173
17.5 Check in g the headlight sett in g ........
210
14.10.15 Cleaning the chain .................. .. .
175
17.6
Ad justing the ile adl igh t ra nge .......... 211
14.10.16 01Pening the chain .. .. .. .. ........ .. . .. 176
14.10.17 Rivet in g the chain ............ .. ........ 176
18 COMB I NATION INSTRUMENT ................... 213
14.10.18 Ch ec king the rear hub damping
18 .1 Com bination instrument .............. .. . 213
ru bb er pieces ............................ 177
18.2 Activati on and test ......................... 213
14.10.19 Changi ng all the damping
18.3 Day-night mocle .. .................. .. ....... 213
rubber pieces of th e r ea r hub ...... 1 78
18.4 Warnin gs ................................ ....... 214
14.10.20 Changing the d ri vetrain ki t.. ..... .. .
179
18.5 Ice warning ...................................
214
15 WIRING HARNESS, BATTERY ..... .. .. ......... .. 182
18.6 Indicator lamps.............................. 215
18.7 Displ ay ......................................... 216
15.1 Removing the 12-V battery.............. 182
18.8 RAL LY display ............................. .. 217
15.2
In stalling the 12-V battery . .. ....... .. ..
183
1 8.9
Speed ...........................................
21 8
15.3 Disconnecti
ng the negative cable 18.
10 Sh i ft warning lig ht ..................... .. .. 218
of the 12 -V battery................. .. .. . .. . 18 5 18.11 Speedometer ...........................
.. .. ..
21 8
15.4 Connecti ng th e negative ca ble of
the 12-V battery.............................
185
18.12
Cru ise control indicator (optional}....
219
15.5 Charging the 12-V battery ............... 186
18.13
Ride display ... .. .. ...........................
219
15 .6 Changing the ma in fuse ...... .. .... ...... 1
87
18 .1 4
ABS d is play. .. ................................
21 9
15.7 Changing the fu ses of individu al
18.15
MTC di sp lay ............... .. .................
219
power consume rs .... .. ..................... 188 18.
16 Coolant temperature i nd icator ......... 220
15.8 Ch ecking the charging volta ge . .. ...... 190
18 .1 7
Fu el l evel display ........... .. .. ............
220
15.9 Checking the
open -cir cu it current.. ..
19 0
18.18 Ambient air temperature indicator ... 221
18.19 Time ............................................. 221
16 BRAKE SYSTEM ........................ .. .......... .. . 19 1
18.20
Favorites displ ay ............. .. ............. 221
16.1 Checking t he front br ake lini ngs ...... 191 18.21 Quick Selector 1 display .
.. .. ....... .. ... 221
16.2 Changing the front br ake lini ngs ...... 191 18.22
Qu i ck Selector 2 display ........... .. ....
222
16.3 Checking the front
bra ke fluid 18.23
Nav igati on display (op tional) ...........
222
l evel .. .................... .. ......... .. .. ........ 193
18.24
Setti ng the service interval
16.4 Add ing the front brake fluid ............ 194
display. .. .. ..... . .. .... ......................... 222
16.5 Changing the f ro nt bra ke fluid.........
195
18 . 25 Menu . .. ............ .. ........ .. ................. 223
16.6 Adjusting the ba sic po si tion of the 18.25.1
KTM MY RI DE (optional) .......... ..
223
hand brake le ver ............................ 197 1
8.25.2
Audio (op tional) ......................... 223
16.7 Checking t he rear brake lini ngs ..... .. 19 7 18.
25 .3 N av igat ion (optional) .. ................ 224
16.8
Chan g in g the br ake pads of the 18.25.4 N
av i ga tion Setup (opt iona l}.........
225
rear wh eel brake .......... .. .. .............. 198
18.2 5.5
Volume (optional) ......................
225
16.9 Checking the
free travel of the foo t
18.25.6
Pairing (optional} .......................
226
brake lever ......... .. ........ .. ............... 2 00
18 . 25.7 Pho ne (op ti ona l) ........... .. ...........
226
16. 10 Adjusting the basic pos ition ot the 18.25.8 Headset (optional) ..................... 227
foot brake l ever .. ....... .. ......... .. ........ 201
18 . 25. 9 Te lepho ny (opti ona l) .. ................
228
16. 11 /\djusting foot brake lever stub ........ 2·02
18 . 25 .10 Trips/Data ................. .. . .. .. .........
229
16.12 Checking the rear brake flu id
18.25.11 G ene ral Info .............................. 229
le vel .. ................... .. ...................... 2·02
18.25.12 Trip 1 .. . .. ............... .. .................
229
16.13 Adding rear
brake flui-d................ .. . 2·03 18.
25.13 Trip 2 .......................................
230
16. 14
Changing the rear br ake flu id ..........
20 4 18.25.14
TP MS........................ .. .. ........... 231
16 .15 Bleeding the brake system .. .. .. .. .... ..
206
18. 25 .15 Wa rn ing.................................... 231
17 LIGH TI NG SY STE M, IN STRUMENTS .. ........ 2 07 18.25.16 Ride Mod e ......... .. ................... .. 232
17.1
Prog ra mming the i gn i ti on key ..... .. . ..
2· 07
18.25.17
Ri de Mode .......................... .. ....
232
17.2 R em oving the h ea dlight mask with
18.25.18
Rally.......... .. .............................
232
the headlight .............................. .. . 207
18 . 25 .19 Throttle R es pon se .......... .. ..........
233
17.3 In stalling the headlight mask with
18.25 .20 L ea ve Rally ... ...................... .... .. 233
the headlight ... .. .. . .. .. ...... .. .............
209
18. 25.21
Motorcycle . .. .. ........................... 233
18.25.22
MTC ................... .. ....................
234
4

18.25.23 ABS .......................................... 234
18 .25. 24 ABS .................................. .. . .. ... 235
18 .25. 25 Quick Shift + (optional) .. .. .. .... .. . .. 235
18.25.26 Settings.................................... 235
18 .25.27 Favorites................................... 236
18.25.28 Quick Selector 1.. .. .................... 236
18.25.29 Quick Selector 2 ........................ 236
18.25. 30 Bluetooth (optional} ........ .. .... .. ... 237
18.25.31 Display Th eme..... .. .................... 237
18.25.32 Sh i ft Light ................................ 237
18.25.33 Lights up ....................... .. ......... 238
18.25. 34 Flashes ..................................... 238
18.25. 35 Sh i ft Light ................................ 238
18 .25.36 Se tting the tim e and date .. ...... ... 239
18.25.37 DRL .. ............................ .. ......... 239
18 .25.38 Units .. .............................. .. ...... 240
18 .25. 39 Distance ......... .. ........................ 240
18.25.40 Temperature............ .. ................ 241
18.25.41 Fuel Cons .................................. 241
18.25.42 Language .............. .... ..... .. ......... 241
18.25.43 Service ............. .. ...................... 242
18.25.44 E tra Fl•nctions ......................... 242
19 ENGINE ................................................... 243
19.1
19.2
19.3
19.3 .1
Removing the eng in e...... .. .. ....... .. ... 243
Installing the engi ne ....................... 251
Engine disassembly......... .. .. ........... 260
19.3.2
19.3.3
19.3.4
19.3.5
19.3.6
19.3.7
19.3.8
19.3.9
19.3.10
19.3.11
19.3.12
19.3.13
19.3. 14
19.3.15
19.3.16
19.3.17
19.3.18
19.3.19
19.3.20
19.3.21
19.3.22
Clamping the engine into the
engine assemb ly sta nd .. ............. 260
Dra ining the engi ne oil .. ........... .. 261
Removi ng the oil filter................ 261
Removing the starter motor......... 262
Removi ng the valve cover............ 262
Removing sh i ft shaft sensor ..... .. . 263
Removing the gea r pos ition
sens or ....................................... 263
Removing the spacer.................. 264
Removing t he a lt ernator cove r..... 264
Removing the torque limiter and
starter idler gear .. .... .. ................ 265
Removi ng the cra n ks haft speed
sensor....................................... 2 65
Removing the heat exchanger...... 266
Remo ving the thermostat... .. .. ..... 266
Removing the wa ter pump
impell er .. .................................. 267
Removing the clutch co v er .... . .. .. . 267
Removing the clutch discs .......... 268
Removing the clutch basket........ 269
Removing locking lever............... 270
Removing the shi ft sha ft............. 270
Removi ng t he spa rk p lu gs ... .. .... .. 27 1
Removi ng the camshafts .. .. . .. . .. ... 27 1
Removing the cylinder head ........ 273
TABLE OF CONTENTS
19 .3.23 Removi ng the timing chain
r ai ls .. ........................................ 274
19 .3.24 Removing the ro tor..................... 274
19.3.25 Removi ng the oil pan .. .. .. ........... 275
19 .3.26 Re mov i ng the oil pump un it.. ...... 276
19 .3.27 Removi ng the engine case
downwards ............ .. ............ ...... 277
19.3.28 Removi ng the transmissi on
shafts ....... .. .......................... .... 278
19.3.29 Removi ng oi l spray t ube ............. 280
19.3. 30 Removi ng the pist on . .. ........... .. .. 280
19.4 Worki ng on i nd ividual parts............. 282
19.4.1 Checking the radial clearance of
cran ks haft bea rings.... .. .............. 282
19.4.2 Changi ng the main bearing
shells ....................................... 283
19 .4 .3 Checking the balancer s·haft .. ...... 284
19.4.4 Working on the upper section of
the engine case .... .. ................... 284
19.4.5 Working on the lower section of
the engine case .............. .. ......... 287
19.4.6 Se lecting the main bearing
shells ................ .. ..................... 2 87
19.4.7 lnstalIi ng the primary gear
wh ee l ................................. ...... 288
19.4.8 Changing the sha ft sea l ri ng of
the water pump ......................... 288
19. 4. 9 Checking the rad ia l clearance of
lowerconrod bearing .................. 290
19.4.10 Changing the conrod beari ng ....... 290
19 .4.11 Cyl inder -Nikasil@coating .......... 292
19.4.12 Checking/measuring the
cylinder ............. .. ..................... 292
19.4.13 Che cking/measuring the piston.... 293
19.4.14 Checking the piston ri ng end
gap.......... .. ........ .. ..................... 2 94
19.4.15 Determini ng the piston/cylinder
mounting clearance .. .................. 294
19 .4.16 Removi ng the oil pumps............. 295
19.4.17 Ch ec king the oil pumps for
w ea r .......... .. .. .......... .. ....... .. ...... 296
19.4.18 Checking the oiI pressure
co ntrol val ve .. ..................... .. . .. .. 297
19.4.19 Installi ng the oil pumps.............. 298
19.4.20 Prepari ng tim in g chain tensioner
for installation .. ......................... 299
19.4 . 21 Che cking the timi ng assembly..... 300
19.4.22 Work ing on the camsh aft
bearing bridge ........................... 301
19.4.23 Wor k in g on the cylinder head ...... 302
19.4.24 Checking the cylinder head ......... 307
19.4.25 Checking the clutch .. .. ............... 309
19.4.26 Removing the shi ft drum
locating un it... .. .... .. ............. .. .... 310
19.4.2/ Ch ec king the sh i ft mechanism .... 311
19.4.28 Preassembli ng the s hi ft shaft.. .. .. 312
5

TABLE OF CONTENTS
19.4.29 Installing the shift drum 20.2 Checki ng the clutch .......................
350
locati ng unit..............................
313
19.4.30 Disassembling the main shaft ..... 314
21
SH I FT MECHAN I SM ..................................
359
19.4.31 Disassembling the 21.1 Check
in g the basic posi ti on of the
countershaft.................. .. ........ .. 315
sh i ft l ever ...................................... 359
19.4.32 Checking the transmission .. ........
316
21.2 Adjusting the
!basic positi on of the
19.4.33 Assembling the ma in shaft.......... 317
shift l ever .. .... ................................ 359
19.4.34 Assembli ng the counter sha ft .......
318
21.3
Cha n gi ng the gear position sensor....
359
19.4.35 Checki
ng the electric starter 21.4 Programming the
gear position
drive................................ .. ....... 320
sensor..... .. .. .. ................................ 361
19.4.36 Checking the freewheel ........... .. . 321 21.5
Cha ngi ng t he shi ft shaft sensor ....... 362
19.4.37
Wo r ki ng on the alternator cove r ...
321
21.6
Prog ramming the shift sha ft
19.5 Engine assembly............................ 322
sensor........................................... 363
19.5.1 Installing the piston ................... 322
22 WATER PUMP, COOLING SYSTEM ........... .. 364
19.5.2 Installi ng the oil spray tube...... .. . 324
19.5.3 Installi
ng the transm i ss i on
22.1 Checking the coolant fill level and
shafts ......... .. ......................... .. . 324
antifreeze... .. ................................. 364
19.5.4 Installi ng the lower e ng i ne
22.2 Checking the coolant level in the
case ........ .. ...... .. .. .. ....... .. .... .. .... 326
compensati ng tank.........................
365
19.5.5 Installing the oi l pump unit......... 329
22.3 Drain ing the coolant........ .. ....... .. . .. . 366
19.5.6 Installing the oil pan ..................
329
22.4 Fi ll ing/bleeding the cooling
19.5.7 Installing the rotor ........... .. .... .. ..
330
system .......................................... 367
19.5.8 Installing the
timing chain ra i ls ...
331
22.5 Changi ng the coolant...................... 368
19.5.9 Installi
ng the cylinder head.........
331
22.6 Correcting the coo lant level in the
19.5.10 Installing the camshafts ............. 333
compensating tank .. ....................... 370
19 .5.11
Che cking the valve clearance ......
336
23 CYLINDER HEAD ...................................... 371
19.5.12 Adjusting the valve,clearance ...... 337
23 .1 Check in g the va l ve clearance .... .. . .. . 371
19.5.13 Installi ng the spark plugs............ 338
23.2 Adjusting t he va l ve clearance .......... 378
19.5.14 Installing the shi ft shaft ........ .. ... 338
19.5.15 Installing the locking lever .......... 339
24 LUBRICATION SYSTEM ............................. 379
19.5.16 Installing the e lu te h basket......... 339
24.1 Oi l cir cuit ...................................... 379
19.5.17 Installing the clutch discs........... 340
24.2 Checking the engine oil level........... 379
19.5.18 Installing the eluteh cover .. ........
341
24.3 Checking the oil pressure .. ..............
380
19.5.19 Mounting the water pump 24.4
Cha ng in g the engine oil and oil
cover ........................................ 342 filter, cleaning the oil screens .........
38 1
19.5.20 Installing the thernnostat.............
342
24.5 Add ing engi ne oil ........................... 383
19.5.21 Installi ng the heat exchanger ......
343
24.6 Checking/cleaning the oil nozzle for
19.5.22 Installing the crankshaft speed clutch lubri
ca t ion ........................... 384
sensor...... .. ...... .. ................. .. ....
3.43
19.5.23 Installi ng torque limiter and 25 IGNITION
SYSTEM .. ..... .. ...........................
389
starter id l er gear ..................... .. .
344
25.1 Alternator -checking the stator
19.5.24 Installing the alternator cover...... 344
winding............................... .. ........ 389
19.5.25 Installing the spacer................ .. . 345
25.2 Ignition
co il -checking the primary
19.5.26 Installing the gea r positi on
winding......................................... 391
sensor....................................... 345
25.3 Changing the spark pl
ugs ................ 392
19.5.27 Installing the shi ft sha ft sensor ... 346
19.5.28 Installing the valve cover ............
347
26
TH RO TTLE VAL VE BO DY ...........................
396
19.5.29 Installing the starter motor.......... 348
26.1 Performing the initi al ization run ......
396
19.5.30 Installing the oil filter .............. .. . 348
26.2 Adjusti
ng serv i ce display with KTM
19.5.31 Installing the oil drain pl
ug ......... 349
diagnostics too l. .. ...........................
396
19.5.32 Removing the engine from the 27 TECHNI
CAL DATA .....................................
398
engine assembly stand ............... 349
20 CLUTCH ..... .. .. ........................................ .. 350
27.1 Engine .......................................... 398
27.2
To lerance, engine wear limits ..........
399
20.1 Adjusting the clutch r•elease lever .... 350
27.3 Engine tightening torques ............... 400
6

TABLE OF CONTENTS
27.4 Capaciti es ...... .. .......................... . .. 403 33 AUX I LIARY SUBSTANCES ....................... .. 466
27.4.l Engine oil ............................... .. 403
27.4.2 Coolant ........... .... . .. . .... ......... .. .. . 40 3
34 SPEC IA L TOOLS .............. .. ................. .... .. 468
27.4 .3 Fuel .. ... .. .................................. 403 35 STANDARDS ......................... .. ................. 486
27.5 Chass is........ .. .. ............................. 403 36
INDEX OF SPECIAL TERMS ............ .. ......... 487
27.6 Electrical syst em ............................ 404
27.6.1 Diagnostics co,nnector ................ 404 37 LIST OF
ABBR EVI ATIONS .......................... 488
27.6.2 Fro nt ACCl and ACC2 ................ 404
38 LIST OF SYMBOLS ......................... .. ......... 489
27.6.3 ACCl and ACC 2 rear .................. 405
27.7 Tir es .. .......... .. .. ............................. 405 38.1 Red symbols
.. .......................... .. .... 489
27.8 Fork .. .. ............................ .. . .. ....... .. 405
38.2 Yell ow an d orange symbo ls.............. 489
27.9 Shock absorber.............................. 406
38.3 Green and blue symbols............ .... .. 489
27.10 Chassis tightening to rque s.... .. ...... .. 406 IND EX............................................................. 490
28 CLEAN I NG/PROTEC T IVE TREATME NT........ 410
28.1 Cl ea ning the mo torcycle .. ......... .. .... 410
28 .2 Checks an d mainten ance st eps fo r
winter operati on ............................. 411
29 STORAGE .. .............. ...... .. . .. .. . .. . .. . .. ......... .. 412
29.1 Storage ......................................... 412
29.2 Preparing fo r use after stor age . .. ...... 41 2
30 SERVICE SCHEDULE ........................... .. ... 413
30.1 A dd it ional informat ion .................... 413
30.2 Req ui red work ............... .. .. . .. ......... 41 3
30.3 Recommended work .. ................... .. 414
31 WIRING DIAGRAM ............ .. .... .. ................ 416
31.1 Page 1 of 12 (EU) .... . .. ................... 416
31.2 Page 2 of 12 (EU) .. . .. . .. ............. .. . .. 418
31.3 Pa ge 3 of 12 (EU) .. ............. .. ......... 420
31.4 Page 4 of 12 (EU) .. ........................ 422
31.5 Page 5 of 12 (EU)......... .. ............... 424
31.6 Page 6 of 12 ( EU) .. .......... .. . .. ......... 426
31.7 P age 7 of 12 (EU) .. ............. .... . .. .... 428
31.8 Pa ge 8 of 12 (EU). .. .. .. ,.................. 430
31.9 Page 9 of 12 (EU) .... ........... .. . .. .. .... 432
31.10 Page 10 of 12 (EU)................. . .. .... 434
31.11 Page 11 of 12 (EU) .. ...................... 436
31.12 Page 12 of 12 (E U) ........................ 4 38
31.13 Page 1 of 12 (U S) ...... ...... ........... .. . 440
31.14 Page 2 of 12 (US).......................... 44 2
31.15 Page 3 of 12 (US) .... .............. .. ...... 444
31.16 Page 4 of 12 (US) .. ........................ 446
31.17 Pa ge 5 of 12 (US).......................... 448
31.18 Page 6 of 12 (US).............. .. ..., .. . .. . 450
31.19 Page 7 of 12 (U S) .. ................., .. .... 452
31.20 Page 8 of 12 (US) .. .. . .... ...... .. . .. .. .... 454
31.21 P age 9 of 12 (US) .. ................ .. ...... 456
31.22 Page 10 of 12 (US).................. .. .... 458
31.23 Pa ge 11 of 12 (U S) .. ...................... 460
31.24 Page 12 of 12 (US). .. ..................... 462
32 SUBSTANCES .................. .. .................... .. 464
7

1 MEANS OF REPRESENTATION
1.1
Symbols used
The meaning of specific symbols is described below.
✓
Indicat es an expected reaction (e. g. of a work step o-r a function).
X Indicates
an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more informat ion is provided on the specified page) .
• !Indicates information with
more details or tip s.
I
» l1ndicates the result of a testing step.
V !Indicates a voltage measurement.
A Indicates a cu
rre nt measurement.
0 Indicates a resistance measurement.
!Indicates the end of an activity includi ng potential rework.
1.2 Fo rmats used
The typographical formats used in this document are expla in ed below.
Proprietary name
Name ®
Brand™
Underlined terms
8
Indicates a proprietary name.
Indicates a protected name.
Indicates a brand ava ilable on the open market.
Refer to techniical de tails of the ve hicle or indicate technical terms, which
are explained in the glossary.

SAFETY ADVICE 2
2.1 Repa ir Manual
Read this Repa ir Manual careful ly and thoroughly before beginning work. It contains useful information and tips
to help you repair an d service your ve hic le.
This manual assumes that the necessary speciaI KTM too ls and KTM workplace and workshop equipment are
available.
2.2 Safe~ advice
A number of safety instructions need to be fol l owed to operate the product described safel y. Therefore read this
instruction and all further instructions included carefull y. The safety instructions are hi gh li ghted in the text and
are referr ed to at the re leva nt passages.
•
Info
I Various information and
warn ing labels are attached in prominent locations on the product described. Do
not remo ve any information or warn in g labels. If t hey are missing, you or others may not recognize dangers
and may therefore be injured.
2.3
A
A
Note
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably l ea d to fatal or serious perman ent injury if the
appropriate measures are not take n.
Warning
Iden tif ie s a danger that is likely to l ead to fatal or serious injury if the appropriate measur es are not
taken.
Caution
Identifies a danger that may le ad to minor injuries if the appropriate meas ures are not taken.
Identifies a danger that wi II l ead to consi de r ab le machine and material damage if the appropriate measu res are
not taken.
~
Note
Indicates a danger that will l ead to en viro nm ental damage if the appropriate measures are no t taken.
2.4 Work rules
Speci al tools are necessary for ce rtain tasks. The tools are not a component of the veh icl e, but can be ordered
us ing the number in parenth eses . Exam ple: bearing puller (15 1 12 01 70 00)
During assembly, use new pa rts to rep l ace parts which ca nnot be r eused (e. g. se l f- locki ng screws and nuts, seals,
sealing rings, 0-ri ngs, pi ns, and lock wash ers).
In the case of certa in screws, a screw adhesive (e.g. Loctite ®) is required. Obse rv e the manufacturer's instruc-
tions.
After disassembly, cl ean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completi ng a rep air or service work, check the operating safety of t he veh icl e.
9

3 IMPORTANT NOTES
3.1 Manufacturer and implied warranty
The work specified in the se rvice schedule may only be performed in an authorized KTM workshop a nd must be
recorded in both the Service & Warran ty Booklet and in the KTM Dealer.net , otherw is e any wa rranty cove rage w il l
become void. Damage or secondary damage caused by tampering with and/or conversions on th e veh icle is not
covered by the manufacturer warranty.
Additional informati on on the manufacturer or manufacturer warranty and the procedures invol ved can be found
in the Service & Warran ty Booklet.
3.2
Fuel auxiliary substances
Note
Environment al haza rd I mp roper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
U se the opera tin g and auxiliary substances (such as fuel and lubr icants) specified in the manual.
3.3 Spare parts, accessories
Only use spare pa rts and accessories approved and/or recommended by KTM. KTM accepts no liability fo r o th er
products and any resulting damage or l oss.
The current KTM PowerP a rt sfor yo ur veh icle can be found on the KTM website.
International KTM Webs ite: http://www.ktm.com
3.4 Figures
The fi gures contained in the manual may dep ict special equipment.
In th e interest of clar ity, some components may be shown disassembled or may not be shown at all. It is not
al ways necessary to disassemble the component to perform the activity in question. Please follow the inst r uct ions
in th e tex t.
10

4.1 Vehicle identification number
40 2324- 10
4.2 Type label
SERIAL NUMBERS 4
The veh icle identificati on number O is stamped on the right side
of the steering head.
( EU )
T he type l abe l O is located on the frame on the left.
The type l abe l for Australia @ is located on the frame on the
right.
(US)
The USA type label O is located on the frame on the left.
The Canada type label @ is located on the frame on t he righ t.
11

4 SERIAL NUMBERS
4.3 Key number
COOE n
VO J2 00 - IO
4.4 Engine number
HOJ0 47 •LO
4.5 Fork part number
.0
402295 - 10
The key number Q can be found on the KEYCODECARD .
•
I Info You need the key number to order a spare key. Keep
the KEYCODECARD in a safe place.
The engine number O is stamped onto the engine case at the
top.
The fork p art number O is stamped on the inner side of the fork
stub.
4.6 Shock absorber article number
402339-10
12
Shock absorber article number O is attached the top of the
shock absorber.

SERIAL NUMBERS 4
4.7 Steerin 1 damper article numb er
Irn1 ss1 - 10
Steering damper article number O is embossed on the underside
of the steering damper.
13

5 MOTORCYCLE
5.1 Liftin1 the motorcycle with the front liftin1 1ear
Note
l!lange r of dam age The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
5.2
Note
402345-01
Prep a ratory work
-Raise motorcycle with rear lifting gear. ( 11.' p. 15)
-Remove the front fender. ( p. 140)
Main wor k
-Move the handlebar to the straight-ahead position.
-Attach the front l ift ing gear wi th the adapters on the steering
sitem.
Mounting pin (69329965040) (0 p. 477)
Front wheel work stand, large (69329965100) ( [ill p. 477)
- Align th e front Iif ti ng gear with the for k legs.
• Info
I Al ways raise the motorcycle .at the rear first.
- Lift the motorcycle at the front.
Takin the motorcycle off the front lifting gear
l!langer of damage The parked veh icle can ro ll away or fall over.
- Park the vehicle on a firm and level surface.
Main work
-Secure the motorcycle aga inst falling over.
-Remove the front li ftin g gear.
312029-10
Fini s hin g work
-Install the front fender. ( p. 140)
14

MOTORCYCLE 5
5.3 Raisin g the motorcyc le with rear lifting gear
Note
D anger of damage The parked vehicle can roll away or fall over.
-Park the vehicle on a fi rm and level surface.
-Mount retaining adapter on the link fo rk.
- Insert adapter·in the rear lift i ng gear.
Retaini ng adapter (61029955144 ) (u p. 473)
Rear w he el work stand (69329955000) (~ p. 477)
-Stand motorcycle upright, align lifting gear to the lin k fork with
the adapters, and ra i se motorcycle.
40 2346-01
5.4 Removing the rear of the motorcycle from the lifting gear
Note
D anger of damage The parked! vehicle can roll away or fall over.
-Park th e vehicle on a fi rm an d l eve l surface.
-Secure the motorcycle against falling over.
-Remove the rear li fting gear and l ean the vehicle on side
stand O.
-Remove the retaining adapter from the link fork.
402029-10
5.5 Raising the motorcycle at the rear using the work stand
Note
D anger of damage The par kecl vehicle can roll away or fall over.
-Park the vehicle on a firm and level surface.
Preparatory work
-Remove the ma in silencer. (" p. 100)
Main wor k
-Remove n ut O.
-Take off footrest rubber and ho lder.
15

5 MOTORCYCLE
-Mount special tool 8 .
IWork sta nd attac hm ents (75029036000) ( 1 p. 478)
-Repeat these steps on the opposite side.
-Mount special tool @) .
IWork sta nd (62529055200) ( p. 475)
-Positi on motorcycle uprig ht , align special tool, and raise
motorcycle.
5.6 Removing the motorcyc le from the work stand at the rear
Note
Danger of damage The parked veh icle can rolI away or fall over.
- Park th e veh ic le on a firm and level surface.
Main wo rk
-Secure the motorcycle aga inst falli ng over.
-Remove special tool O and 8 .
Work sta nd (625 290552 00) ( p. 475)
Work stand attachments (75029036000) ( !J!i p. 4 78)
-Positi on footrest rubber wi th holder.
-Mount and tighten nut 8 .
Guideline
Rema ining nuts,
chassis M6
-Repeat these steps on the opposi te side.
Fini s hin g work
- Install the main silencer. ( p. 100)
5.7 Raisin1 the motorcycle at the front usin1 the work stand
Note
Dan ger of da mage The parked vehicle can rolI away or fall over.
- Pa rk th e v ehic le on a firm and level surface.
Preparatory work
-Remove the seat. (~ p. 114)
-Remove the le ft side cover. ( r. p. 130)
-Remove the battery cover. (~ p. 131)
-Remove left fuel tank spoiler. ( ,;! p. 132)
-Remove the right side cover. (i p. 130)
16
10 Nm (7.4 lbf ft)
41

MOTORCYCLE 5
-Remove right fuel tank spoiler. ( p. 134)
-Remove engine guard. ( p. 138)
-Remove the fuel tank. ( ..I p. 114)
Main work
-Remove the cable ties.
-Remove screws O.
-Mount the special tool.
I Work stand (62529055200) (l'' p. 475)
-Stand the motorcycle upright, align the special tool, and raise
the motorcycle.
5.8 Removing the motorcycle from the work stand at the front
Note
D anger of damage The parked vehicle can roll away or fall over.
-Park the vehicle on a firm and level surface.
Main work
-Secure the motorcycle against falling over.
-Remove the special tool.
I Work stand (62529055200) (L p. 475)
-Mount and tighten screws O.
Gu ideli ne
Remaining screws,
chassis
M8 25 Nm (18.4 lbf ft)
-Mount t he cable ti es.
Finishing work
- Install the fuel tan k. ( I!',;:! p. 117)
- Install the engine guard. (~ p. 138)
- Install the right fuel tank spoiler. (I p. 135)
17

5 MOTORCYCLE
-Install the right side cover .( ~ p. 131)
- Install the left fuel tank spoiler. ( p. 133)
-Install the battery cover. ( !.ll p. 132)
-Install the left side cover. (a p. 130)
-Mou nt th e sea t. ( p. 114)
5.9
Starting the vehicle
Danger
D ange r of poison in g Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
-Always make sure there is s uffi cient ven tilat ion when runningthe engine.
- U se effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High re vv ing speed with a co ld engi ne negatively impacts the lifespan of the engi ne.
-Alw ays ru n the engine warm at a low speed.
0 ®
(j)
80 0782-10
18
- Ta ke the motorcycle off the side stand and si t on the motorcy-
cl e.
-Make sure that the emergency OFF switch/electric starter but-
ton is in the middle po sition 0 .
-Switch on the ignition by turning the i gn ition k ey to the posi-
ti on 0 .
✓ After yo u switch on the ign it ion, you can hear the fuel
pump wo rking for about t wo seconds. Th e func tio n check
of the combinati on instrument is run at the same time.
✓ Th e ABS warning lamp lights up and goes back out after
starting off.
-Shift the transmission into neutral m.
✓ The green idle indi ca tor lamp N lights up.
-Turn emergency OIFF sw itch/electric starter button to the lower
positi on (i) .
• Info
I Do not press th e emergency off switch/electr ic sta rt er
button into th e lower pos i tion (i) until the combination
instrument functi on check has been completed.
Whe n sta rt i ng, DO NOT ope n the throttle. If you open
the throttle during the starting procedure, fuel is not
inject ed by the engine management system and the
engine cann ot star t.
Press the emergency OFF switch/electric starter button
into the lower positi on (i) for a max imum of 5 seconds.
Wait for a least 5 seconds before trying again.
This motorcycle is equipped with a safety starting sys -
tem. Yo u can only start the engine if the transmission
is in neutral or if t he clutch lever is pulled when a gea r
isengaged. If the side stand is folded ou t and you shift
into gea r and release th e clutch l ever, th e engine stops.
41