KTM 690 DUKE EU Owner's Manual
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KTM 690 DUKE EU Owner's Manual

2011
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See also: Owner's Manual
OWNER'S MANUAL
2011
690 Duke EU
690 Duke AUS/UK
690 Duke R EU
690 Duke R AUS/UK
690 Duke R JP
Art. no. 3211664en

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Summary of Contents for KTM 690 DUKE EU

  • Page 1 OWNER'S MANUAL 2011 690 Duke EU 690 Duke AUS/UK 690 Duke R EU 690 Duke R AUS/UK 690 Duke R JP Art. no. 3211664en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you DEAR KTM CUSTOMER enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Combination instrument - time .......... 28 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........6 Setting the clock .............. 28 IMPORTANT INFORMATION ........... 7 Combination instrument - display ODO ....... 29 VIEW OF VEHICLE..............12 Combination instrument - setting/resetting TRIP 1....29 View of vehicle, front left (example)........
  • Page 6 TABLE OF CONTENTS Stopping, parking ............. 50 Adjusting basic position of clutch lever....... 76 Refueling................. 51 Checking/rectifying the fluid level of the hydraulic clutch ..76 SERVICE SCHEDULE............54 BRAKES ................78 Service schedule .............. 54 Adjusting the basic position of the hand brake lever..... 78 TUNING THE CHASSIS............
  • Page 7 TABLE OF CONTENTS Installing the headlight mask with the headlight ....109 CLEANING, CARE .............. 143 Changing the low beam bulb..........110 Cleaning the motorcycle ..........143 Changing the high beam bulb .......... 113 Protective treatment for winter operation ......145 Changing the parking light bulb ........

  • Page 8: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed in an authorized KTM workshop! There, your motorcycle will be serviced opti- mally by specially trained experts using the specialist tools required.

  • Page 9: Important Information

    Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth- erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 10 Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 11 IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – 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.
  • Page 12 IMPORTANT INFORMATION Grades of risks 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.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 601261-10...
  • Page 15 VIEW OF VEHICLE Combination instrument ( p. 24) Rear mirror Clutch lever ( p. 19) Seat Handrails ( p. 35) Fork compression adjustment Fuel taps ( p. 33) Shift lever ( p. 36) Engine number ( p. 16) Side stand ( p.

  • Page 16: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) 601262-10...
  • Page 17 VIEW OF VEHICLE Seat lock ( p. 34) Light switch ( p. 20) Headlight flasher switch ( p. 21) Turn signal switch ( p. 21) Horn button ( p. 22) Filler cap Emergency OFF switch ( p. 22) Electric starter button ( p.

  • Page 18: Serial Numbers

    SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the right of the steering head.  The type label is on the right of the frame behind the steering head.  500006-01 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. ...

  • Page 19: Key Number

    SERIAL NUMBERS Key number 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. 100179-10 Fork part number The fork part number is stamped on the inner side of the fork stub.

  • Page 20: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the  adjusting ring toward the rear. 700128-01...

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 100114-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. ...

  • Page 22: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar.  601263-10 Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on.

  • Page 23: Headlight Flasher Switch

    CONTROLS Headlight flasher switch The headlight flasher switch is fitted on the left side of the handlebar.  Possible states • Headlight flasher switch in neutral position Headlight flasher switch pressed – In this position, the headlight flasher (high beam) •...

  • Page 24: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar.  Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 500021-11 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 25: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar.  Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button 500022-11 Ignition/steering lock 5.10...

  • Page 26: Combination Instrument

    CONTROLS Combination instrument 5.11 The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. Function buttons  Tachometer  Indicator lights  Display  400832-10 Combination instrument - function buttons 5.12 You can change the display mode with the MODE button ...

  • Page 27: Combination Instrument - Tachometer

    CONTROLS Combination instrument - tachometer 5.13 The tachometer shows the engine speed in revolutions per minute.  The red marking shows the excess speed range of the engine.  400834-10 Combination instrument - indicator lamps 5.14 The indicator lamps offer additional information about the operating state of the motorcy- cle.

  • Page 28: Combination Instrument - Display

    CONTROLS FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagno- sis) has identified an emissions- or safety-critical fault. Battery warning lamp lights up red – Voltage in vehicle system too low. Combination instrument - display 5.15 When you switch on the ignition, all display segments light up for one second as a function test.

  • Page 29: Combination Instrument - Speedometer

    CONTROLS Combination instrument - speedometer 5.16 The speed is shown in kilometers per hour km/h or in miles per hour mph.  400838-10 Setting kilometers or miles 5.17 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country.

  • Page 30: Combination Instrument - Time

    CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.

  • Page 31: Combination Instrument - Display Odo

    CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –...

  • Page 32: Combination Instrument - Setting/Resetting Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 400840-01 Combination instrument - setting/resetting TRIP 2 5.22...

  • Page 33: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.23 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 400842-01 Combination instrument - coolant temperature indicator 5.24...

  • Page 34: Opening The Filler Cap

    CONTROLS Opening the filler cap 5.25 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 35: Closing Filler Cap

    CONTROLS Closing filler cap 5.26 – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover. 500023-01 Fuel taps 5.27 The fuel taps are located on the left/right under the fuel tank. ...

  • Page 36: Seat Lock

    CONTROLS Seat lock 5.28 The seat lock is located to the right of the seat.  You can lock it with the ignition key. 700131-01 Owner's manual 5.29 You can find the owner's manual in its protective case on the underside of the seat. ...

  • Page 37: Tool Set

    CONTROLS Tool set 5.30 The tool set is located in the storage compartment under the seat.  700134-01 Handrails 5.31 The handrails are used for moving the motorcycle around.  When you have a passenger, the passenger can hold on the handrails during the journey. 700130-01...

  • Page 38: Passenger Footrests

    CONTROLS Passenger footrests 5.32 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • 700135-01 Shift lever 5.33 The shift lever is mounted on the left side of the engine.

  • Page 39: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 700138-01 Foot brake lever 5.34 Foot brake lever is located in front of the right footrest.  The rear brake is engaged with the foot brake lever. 700136-01...

  • Page 40: Side Stand

    CONTROLS Side stand 5.35 The side stand is located on the left side of the vehicle.  The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety electric starter system - see the riding instructions.

  • Page 41: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 42: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 43: Loading The Vehicle

    PREPARING FOR USE Guideline Maximum engine speed During the first: 1,000 km (621.4 mi) 6,000 rpm After the first: 1,000 km (621.4 mi) 7,800 rpm – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. –...
  • Page 44 PREPARING FOR USE Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed properly at regular intervals.

  • Page 45: Riding Instructions

    RIDING INSTRUCTIONS Performing checks and vehicle care when preparing for use Info Before each use, check the state and roadworthiness of the vehicle. Make sure that the vehicle is in perfect technical condition before use. – Check the engine oil level. ( p.

  • Page 46: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous 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.

  • Page 47: Starting Off

    RIDING INSTRUCTIONS Info Do not press the electric starter button until the function test of the combination instrument is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 48 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger must be capable of sitting correctly on the passenger seat.
  • Page 49 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.
  • Page 50 RIDING INSTRUCTIONS – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the six forward gears in the figure.

  • Page 51: Braking

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.

  • Page 52: Stopping, Parking

    RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.

  • Page 53: Refueling

    RIDING INSTRUCTIONS Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over. –...
  • Page 54 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 55 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 32) – Fill the fuel tank with fuel up to measurement  Guideline Level 50 mm (1.97 in)  Total fuel tank 13.5 l Super unleaded (ROZ 95 / RON 95 / capacity, approx.

  • Page 56: Service Schedule

    Check that the electrical equipment is functioning correctly. • • • • • • • • Read out the fault memory using the KTM diagnostics tool. • • • Check the measured service values with the KTM diagnostics tool. • • • •...
  • Page 57 Final check: Check the vehicle for roadworthiness and take a test ride. • • • • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • • Make the service entry in KTM DEALER.NET and in the service record.
  • Page 58 SERVICE SCHEDULE K10N: Once after 1,000 km (621.4 mi) K75A: Every 7,500 km (4,660 mi) or annually K150A: Every 15,000 km (9,321 mi) or every 2 years K300A: Every 30,000 km (18,641 mi) or every 4 years...

  • Page 59: Tuning The Chassis

    TUNING THE CHASSIS 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 Table . You ...

  • Page 60: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS Guideline Compression damping (Duke) Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Compression damping (Duke R) Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior.

  • Page 61: Compression Damping Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screws clockwise all the way.  Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping (Duke) 700145-01...

  • Page 62: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 63: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.
  • Page 64 TUNING THE CHASSIS – Turn adjusting screw all the way clockwise using a socket wrench.  Info Do not loosen nut  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed (Duke) 100843-10 Comfort 2.0 turns...

  • Page 65: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 66: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the front wheel stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle with the rear wheel stand. ( p.

  • Page 67: Raising The Motorcycle With The Rear Wheel Stand

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the rear wheel stand 10.3 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the adapter into the rear wheel stand and screw into the swingarm on both sides. Adapter (61029055110) Rear wheel stand (61029055100) –...

  • Page 68: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS Bleeding the fork legs 10.5 – Lean the motorcycle on the side stand. – Remove bleeder screws briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs.

  • Page 69: Mounting The Seat

    SERVICE WORK ON THE CHASSIS Mounting the seat 10.7 – Suspend the seat on the screw , press the rear downwards and at the same time push  it forwards. The two projections must be inserted into the frame.  –...

  • Page 70: Positioning The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Lay a cloth over the subframe and straighten the steering.  – Carefully raise the fuel tank and move it backwards. – Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat- ing tank (see illustration).

  • Page 71: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS – Carefully move the fuel tank forwards and lower it. – Mount and tighten screw with bearing sleeve and rubber bushing . Check fuel    tank for tight fitting. Guideline Screw, fuel tank bracket 15 Nm (11.1 lbf ft) –...
  • Page 72 SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 73: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Checking the chain tension 10.12 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

  • Page 74: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Adjusting the chain tension 10.13 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.
  • Page 75 SERVICE WORK ON THE CHASSIS – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right ...

  • Page 76: Checking The Chain, Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS Checking the chain, rear sprocket and engine sprocket 10.14 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 77 SERVICE WORK ON THE CHASSIS – Shift into neutral; pull the lower chain section with the specified weight  Guideline Weight of chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. ...

  • Page 78: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS Guideline Screw, chain sliding 10 Nm Loctite ® 243™ guard (7.4 lbf ft) Adjusting basic position of clutch lever 10.15 Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
  • Page 79 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Check the fluid level. The fuel level must be between MIN and MAX. » If the level of the coolant does not meet specifications: –...

  • Page 80: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement ...

  • Page 81: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 82: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Checking The Front Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 100181-10 Checking the front brake linings 11.5 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 84: Checking The Free Travel Of Foot Brake Lever

    BRAKES Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable. Check the brake linings regularly. –...

  • Page 85: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKES – Disconnect spring  – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel  Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) »...

  • Page 86: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 87: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 88 Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 89: Checking The Rear Brake Linings

    11.10 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are rendered unserviceable.

  • Page 90: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 – Raise the motorcycle with the rear wheel stand. ( p. 65) – Raise the motorcycle with the front wheel stand. ( p. 64) – Remove screws and spacers   – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.

  • Page 91: Installing The Front Wheel

    WHEELS, TIRES Installing the front wheel 12.2 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. –...

  • Page 92: Removing Rear Wheel

    WHEELS, TIRES Guideline Screw, front brake caliper M10x1.25 45 Nm Loctite ® 243™ (33.2 lbf ft) – Remove the fixation of the hand brake lever. – Take the motorcycle off of the front wheel stand. ( p. 64) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

  • Page 93: Installing The Rear Wheel

    WHEELS, TIRES – Pull the rear wheel and brake caliper support together to the rear until you can swing  the brake caliper support to the side. Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not damaged. –...
  • Page 94 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Remove spacer . Clean and grease the working surfaces of the bushing and shaft seal ...

  • Page 95: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – Take the motorcycle off of the rear wheel stand. ( p. 65) Checking the rear hub rubber dampers 12.5 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation.

  • Page 96: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 97: Checking The Tire Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years.
  • Page 98 WHEELS, TIRES – Remove the dust cap. – Check the tire pressure when the tires are cold. Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) 400695-01 Rear...

  • Page 99: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 100 ELECTRICAL SYSTEM – Fold up positive terminal cover  – Disconnect the positive (plus) cable of the battery.  – Detach rubber band  700163-10 – Disconnect plug-in connector  – Remove cover  700164-10 – Pull battery up and out of the battery rack. Take the battery out of the frame toward ...

  • Page 101: Installing The Battery

    ELECTRICAL SYSTEM Installing the battery 13.2 – Push battery from the right into the frame. Position the battery in the battery rack.  Info The battery terminals must be at the front. 700165-11 – Position cover  – Connect plug-in connector ...
  • Page 102 ELECTRICAL SYSTEM – Secure the cover with rubber band  – Connect positive cable . Position positive terminal cover   700163-11 – Secure the cover with rubber band  – Attach the minus cable  – Position the fuel tank. ( p.

  • Page 103: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 104 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 105: Changing The Main Fuse

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid ...
  • Page 106 ELECTRICAL SYSTEM Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery. – Switch off all power consumers and switch off the engine. – Remove the seat. ( p.

  • Page 107: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM Changing the fuses of individual power consumers 13.5 Info The fuse box containing the fuses of individual power consumers is located under the seat. – Switch off all power consumers and the engine. – Remove the seat. ( p.
  • Page 108 ELECTRICAL SYSTEM – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10 A - clock, ignition (EFI control unit) Fuse 3 - 10 A - EPT control unit Fuse 4 - 10 A - fuel pump Fuse 5 - 10 A - radiator fan Fuse 6 - 10 A - horn, brake light, turn signal, alarm system (optional)

  • Page 109: Removing Headlight Mask With Headlight

    ELECTRICAL SYSTEM Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. – Mount the seat. ( p. 67) Removing headlight mask with headlight 13.6 –...
  • Page 110 ELECTRICAL SYSTEM – Disconnect plug-in connector. 700171-01 – Remove the screw fitting on both sides.  – Place the headlight mask to one side. 700172-10...

  • Page 111: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Installing the headlight mask with the headlight 13.7 – Position the headlight mask. Mount and tighten screws on both sides.  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) 700172-11 – Connect the plug-in connector. 700171-01...

  • Page 112: Changing The Low Beam Bulb

    ELECTRICAL SYSTEM – Fold the headlight mask up. 700170-11 – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check the lighting function. 700169-11 Changing the low beam bulb 13.8 Note Damage to reflector Reduced luminance.
  • Page 113 ELECTRICAL SYSTEM – Remove screws  700169-10 – Fold the headlight mask forward. 700170-10...
  • Page 114 ELECTRICAL SYSTEM – Turn headlight lamp counterclockwise and remove it. Detach the connector.  – Position the new headlight bulb in the headlight housing. Connect the connector. Low beam/high beam (HB3 / socket P20d) ( p. 162) Info Insert the headlight bulb so that the bayonet lugs latch into the slots. 600828-10 –...

  • Page 115: Changing The High Beam Bulb

    ELECTRICAL SYSTEM – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check lighting function. 700169-12 Changing the high beam bulb 13.9 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 116 ELECTRICAL SYSTEM – Fold the headlight mask forward. 700170-10 – Turn headlight lamp counterclockwise and remove it. Detach the connector.  – Position the new headlight bulb in the headlight housing. Connect the connector. Low beam/high beam (HB3 / socket P20d) ( p.

  • Page 117: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Fold the headlight mask up. 700170-11 – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check lighting function. 700169-12 Changing the parking light bulb 13.10 Note Damage to reflector Reduced luminance.

  • Page 118: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Remove the headlight mask with the headlight. ( p. 107) – Set down the headlight mask in front of you as shown in the illustration and carefully tilt the high beam headlight in the direction of the low beam headlight. –...

  • Page 119: Checking The Low Beam Headlight Adjustment

    ELECTRICAL SYSTEM – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off.  – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket.

  • Page 120: Checking The High Beam Headlight Adjustment

    ELECTRICAL SYSTEM – The rider, with luggage and a passenger if applicable, now sits down on the motorcycle. – Check the low beam headlight adjustment. For a ready-to-operate motorcycle with a rider, and with luggage and a passenger if applicable, the light-dark boundary must lie exactly on the lower mark. »...

  • Page 121: Adjusting The Light Range Of The Low Beam Headlight

    ELECTRICAL SYSTEM Adjusting the light range of the low beam headlight 13.14 – Check the low beam headlight adjustment. ( p. 117) – Remove screws  – Fold the headlight mask forward. 700169-10 – Adjust the beam distance of the headlight by turning screw ...

  • Page 122: Adjusting The Light Range Of The High Beam Headlight

    ELECTRICAL SYSTEM – Fold the headlight mask up. – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) 700169-10 Adjusting the light range of the high beam headlight 13.15 – Check the high beam headlight adjustment. ( p.
  • Page 123 ELECTRICAL SYSTEM – Adjust the beam distance of the headlight by turning screw  Guideline For a motorcycle with rider, the center of the light cone must be exactly on the lower mark (the mark is created in: Checking headlight adjustment). Info Turn clockwise to increase the headlight range;...

  • Page 124: Cooling System

    COOLING SYSTEM Cooling system 14.1 The water pump in the engine forces the coolant to flow.  The pressure in the cooling system resulting from heat is regulated by a valve in the radi- ator cap . The heat expansion causes the surplus coolant to flow into the compensating ...
  • Page 125 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 126 COOLING SYSTEM – Mount the cap of the compensating tank. – Screw off the radiator cap  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant.

  • Page 127: Checking The Coolant Level

    COOLING SYSTEM Checking the coolant level 14.3 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 128: Draining The Coolant

    COOLING SYSTEM – Screw off the radiator cap and check the coolant level in the radiator.  The radiator must be completely filled. » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p.

  • Page 129: Filling/Bleeding The Cooling System

    COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 130 COOLING SYSTEM Condition Fuel tank is reset or removed. – Remove radiator cap  700182-10 – Remove bleeder screw  – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten the bleeder screw immediately.
  • Page 131 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are poisonous 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.

  • Page 132: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3… 5 mm (0.12… 0.2 in) »...

  • Page 133: Adjusting The Play In The Throttle Cable

    Adjusting the play in the throttle cable 15.2 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut  – Set the play in the throttle cable by turning the adjusting screw ...
  • Page 134 TUNING THE ENGINE – Position the Map‑Select switch on the outside of the frame. – Pull the Map‑Select switch out of the holder. 700197-01 – Turn the adjusting wheel until the desired digit is next to marking  Set the Map‑Select switch to Soft. –...
  • Page 135 TUNING THE ENGINE – Position the Map‑Select switch in the holder. – Push the Map‑Select switch with the holder upward onto the retaining bracket. 700196-11...

  • Page 136: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. – Stand the motorcycle upright on a horizontal surface. –...

  • Page 137: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE Changing the engine oil and filter, cleaning the oil screens 16.2 – Drain the engine oil. p. 135) – Remove the oil filter. p. 136) – Clean the oil screens. p. 138) – Install the oil filter. p.

  • Page 138: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring.  – Completely drain the engine oil. 700186-01 – Thoroughly clean the oil drain plug with a magnet. –...
  • Page 139 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Place a suitable container under the engine. – Remove screws .

  • Page 140: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE Installing the oil filter 16.5 – Insert oil filters   – Oil the O-rings of the oil filter covers. Mount oil filter covers   – Mount and tighten the screws. Guideline Screw, oil filter cover (Duke) 6 Nm (4.4 lbf ft) Screw, oil filter cover (Duke R) 6 Nm (4.4 lbf ft)
  • Page 141 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Place a suitable container under the engine. – Remove plug with oil screen and the O-rings.

  • Page 142: Refilling With Engine Oil

    SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings.  – Mount and tighten screw plug with the O-ring.  Guideline Plug, oil screen (Duke) M20x1.5 15 Nm (11.1 lbf ft) Plug, oil screen (Duke R) M20x1.5 15 Nm (11.1 lbf ft) 700193-01...

  • Page 143: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the oil filler plug with O-ring from the clutch cover and fill up with engine  oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 174) Alternative engine Engine oil (SAE 10W/50) p.
  • Page 144 SERVICE WORK ON THE ENGINE – Remove the oil filler plug with O-ring from the clutch cover and fill up with engine  oil. Engine oil (SAE 10W/60) (00062010035) ( p. 174) Engine oil (SAE 10W/50) ( p. 174) Info For optimal performance of the engine oil, do not mix different types of engine oil.

  • Page 145: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 146 CLEANING, CARE Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine is warm, applying the brakes occasionally.

  • Page 147: Protective Treatment For Winter Operation

    CLEANING, CARE Protective treatment for winter operation 17.2 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water. Warm water enhances the corrosive effects of salt. –...

  • Page 148: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 65) –...

  • Page 149: Putting Into Operation After Storage

    STORAGE – Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

  • Page 150: Troubleshooting

    Clean the socket connector and treat it with con- oxidized tact spray. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power. Air filter is very dirty Remove the air filter.
  • Page 151 Air in cooling system Fill/bleed the cooling system. p. 127) – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during the journey Lack of fuel Refuel. ( p.
  • Page 152 TROUBLESHOOTING Faults Possible cause Action – Time is not (correctly) displayed Fuse 2 blown Change the fuses of individual power consumers. p. 105) – Set the clock. ( p. 28) – Battery discharged Ignition not switched off when vehicle Recharge the battery. p.

  • Page 153: Blink Code

    BLINK CODE Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high...
  • Page 154 BLINK CODE Blink code FI of warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Error level condition Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high Blink code FI of warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short...
  • Page 155 BLINK CODE Blink code FI of warning lamp (MIL) 25 FI warning lamp (MIL) flashes 2x long, 5x short Error level condition Side stand switch - circuit fault Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Motor drive hall sensor - circuit fault Blink code FI of warning lamp...
  • Page 156 BLINK CODE Blink code FI of warning lamp (MIL) 54 FI warning lamp (MIL) flashes 5x long, 4x short Error level condition Secondary air valve - short circuit to ground or open circuit Blink code FI of warning lamp (MIL) 58 FI warning lamp (MIL) flashes 5x long, 8x short Error level condition EPT motor drive relay permission - signal fault...
  • Page 157 BLINK CODE Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition Motor drive voltage (internal) - circuit fault...

  • Page 158: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement (Duke) 654 cm³ (39.91 cu in) Displacement (Duke R) 690 cm³ (42.11 cu in) Stroke (Duke) 80 mm (3.15 in) Stroke (Duke R) 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio (Duke) 11.8:1 Compression ratio (Duke R)

  • Page 159: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 3rd gear 21:28 4th gear 21:23 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling...

  • Page 160: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite...
  • Page 161 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, locking lever 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, rocker arm shaft 12 Nm (8.9 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite...
  • Page 162 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –...

  • Page 163: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel Front 140 mm (5.51 in) Rear 140 mm (5.51 in) Brake system Front Disc brake with radially screwed four-piston brake caliper, floating...

  • Page 164: Lighting Equipment

    TECHNICAL DATA - CHASSIS Steering head angle 63.5° Wheelbase 1,472±15 mm (57.95±0.59 in) Seat height unloaded 865 mm (34.06 in) Ground clearance unloaded 155 mm (6.1 in) Weight without fuel approx. 148.5 kg (327.4 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.)

  • Page 165: Tires

    120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL Michelin Pilot Power Michelin Pilot Power Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 166: Technical Data - Fork

    TECHNICAL DATA - FORK Duke 24.1 Fork part number 14.18.7K.09 WP Suspension Up Side Down 4860 ROMA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload...

  • Page 167: Duke R

    TECHNICAL DATA - FORK Duke R 24.2 Fork part number 14.18.7K.46 WP Suspension Up Side Down 4860 ROMA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks...

  • Page 168: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Duke 25.1 Shock absorber part number 15.18.7J.09 WP Suspension 4618 with Pro‑Lever deflector Shock absorber Compression damping, high-speed Comfort 2.0 turns Standard 1.5 turns Sport 1.0 turn Full payload 1.0 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks...

  • Page 169: Duke R

    TECHNICAL DATA - SHOCK ABSORBER Medium (standard) 70 N/mm (400 lb/in) Hard 75 N/mm (428 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Riding sag 60… 65 mm (2.36… 2.56 in) Fitted length 376 mm (14.8 in) Shock absorber fluid...
  • Page 170 TECHNICAL DATA - SHOCK ABSORBER Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Comfort 12 mm (0.47 in) Standard 12 mm (0.47 in) Sport 12 mm (0.47 in) Full payload 15 mm (0.59 in) Spring rate Medium (standard) 70 N/mm (400 lb/in) Hard...

  • Page 171: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, combination instrument holder EJOT 1 Nm (0.7 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 172 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, foot brake cylinder 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, fuel tap Tightening sequence: tighten in parallel 6 Nm (4.4 lbf ft) – Screw, headlight mask 5 Nm (3.7 lbf ft) ®...
  • Page 173 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, main silencer fixation 25 Nm (18.4 lbf ft) Screw, manifold on main silencer 25 Nm (18.4 lbf ft) Copper paste ® Screw, rear brake disc 30 Nm (22.1 lbf ft) Loctite 243™ ®...
  • Page 174 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) – Adjusting ring of swingarm bearing M24x1.5 25 Nm (18.4 lbf ft) – Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) –...

  • Page 175: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 176 179) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
  • Page 177 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 178 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 179: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 180 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Bike Grease 2000 Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline –...

  • Page 181: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 182: Index

    INDEX INDEX Accessories ........8 Chain checking .
  • Page 183 INDEX Coolant draining ........126 Filler cap Coolant level closing .
  • Page 184 INDEX Low beam bulb changing ........110 Hand brake lever .
  • Page 185 INDEX checking ........130 Shock absorber ....... . compression damping, general .
  • Page 186 INDEX Transport ........8 Troubleshooting .
  • Page 187 *3211664en* 3211664en 10/2010 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

690 duke r jp2011 690 duke r690 duke r aus/uk

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