KTM 2016 690 DUKE R Owner's Manual
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KTM 2016 690 DUKE R Owner's Manual

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OWNER'S MANUAL
2016
690 Duke
690 Duke R
Art. no. 3213397en

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Summary of Contents for KTM 2016 690 DUKE R

  • Page 1 OWNER'S MANUAL 2016 690 Duke 690 Duke R Art. no. 3213397en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • 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 Shock absorber article number ......23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 CONTROLS..............24 Symbols used ............7 Clutch lever............24 Formats used............8 Hand brake lever..........24 SAFETY ADVICE.............. 9 Throttle grip ............25 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS Temperature............39 Starting............. 57 Gear display ............40 Starting off............58 Fuel tank capacity..........40 Shifting, riding ..........58 Coolant temperature indicator ......41 Engine braking control (MSR) ......62 "Favorites" ............41 Applying the brakes..........63 7.10 "Trip 1"...
  • Page 7 TABLE OF CONTENTS 12 SERVICE WORK ON THE CHASSIS......... 83 13.8 Adjusting the basic position of the foot brake lever ............107 12.1 Raising the motorcycle with the rear lifting gear..83 13.9 Checking rear brake fluid level ......109 12.2 Removing the rear of the motorcycle from the lifting gear ............
  • Page 8 TABLE OF CONTENTS 15.14 Diagnostics connector ........147 22.3 Capacities ............179 16 COOLING SYSTEM ............148 22.3.1 Engine oil ........... 179 16.1 Cooling system ..........148 22.3.2 Coolant ............179 16.2 Checking the antifreeze and coolant level ... 148 22.3.3 Fuel ............

  • Page 9: 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 by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 10: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 11: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is only authorized for operation on public roads in the homologated version.

  • Page 12: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 13: Safe Operation

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 14: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 15: Owner's Manual

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 16: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 17: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 18: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) K00345-10...
  • Page 19 VIEW OF VEHICLE Clutch lever ( p. 24) Seat Passenger seat Handrails ( p. 32) Seat lock ( p. 31) Side stand ( p. 35) Shift lever ( p. 33) Engine number ( p. 22)

  • Page 20: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) K00413-10...
  • Page 21 VIEW OF VEHICLE Tool set ( p. 32) Light switch ( p. 26) Turn signal switch ( p. 27) Horn button ( p. 28) Filler cap Ignition/steering lock ( p. 29) Emergency OFF switch ( p. 28) Electric starter button ( p.

  • Page 22: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the right side of the steering head. 402324-10 Type label  The type label is located on the right side of the frame. H01126-01...

  • Page 23: Key Number

    SERIAL NUMBERS (690 Duke R AU)  Additional type label is located on the left side of the frame. 402381-11 Key number  can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 24: Engine Number

    SERIAL NUMBERS Engine number  The engine number is located on the left side of the engine under the engine sprocket. 401949-10 Fork part number  The fork part number is stamped on the inner side of the fork stub. 402295-10...

  • Page 25: Shock Absorber Article Number

    SERIAL NUMBERS Shock absorber article number (Duke)  Shock absorber article number is on the left side of the shock absorber. 402382-10 (Duke R)  Shock absorber article number is located on the rear of the shock absorber. 402298-10...

  • Page 26: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. K00347-10 Hand brake lever (Duke)  The hand brake lever is fitted on the right side of the handlebar. K00348-10...

  • Page 27: Throttle Grip

    CONTROLS (Duke R)  The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. V00047-10 Throttle grip  The throttle grip is fitted on the right side of the handlebar. K00349-10 Switches on the left side of the handlebar 6.4.1...

  • Page 28: Light Switch

    CONTROLS Overview of the left combination switch Light switch ( p. 26) Menu switch ( p. 27) Turn signal switch ( p. 27) Horn button ( p. 28) K00357-10 6.4.2 Light switch  Light switch is fitted on the left side of the handlebar. Possible states Low beam on –...

  • Page 29: Menu Switch

    CONTROLS 6.4.3 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the display on the combination instrument.  Button is the UP button.  Button is the DOWN button. ...

  • Page 30: Horn Button

    CONTROLS 6.4.5 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 K00350-10 Switches on the right side of the handlebar 6.5.1 Emergency OFF switch ...

  • Page 31: Electric Starter Button

    CONTROLS 6.5.2 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 K00349-12 6.5.3 Ignition/steering lock...

  • Page 32: Opening The Filler Cap

    CONTROLS Opening the filler cap 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 33: Closing The Filler Cap

    CONTROLS Closing the filler cap – Fold down the filler cap. – Turn the ignition key 90° clockwise. – Push down the filler cap and turn the ignition key counterclockwise until the lock closes. Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. –...

  • Page 34: Tool Set

    CONTROLS Tool set  The tool set is located under the passenger seat. K00414-10 6.10 Handrails  The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. K00415-10...

  • Page 35: Passenger Footrest

    CONTROLS 6.11 Passenger footrest The passenger footrests are foldable. Possible states Passenger footrest folded in – For operation without a passenger. • Passenger footrest folded out – For operation with a passenger. • K00376-10 6.12 Shift lever  The shift lever is mounted on the left side of the engine.

  • Page 36: 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. 401950-11 6.13 Foot brake lever  Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 402177-10...

  • Page 37: Side Stand

    CONTROLS 6.14 Side stand  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 starting system – see the riding instruc- tions.

  • Page 38: Combination Instrument

    COMBINATION INSTRUMENT Overview The combination instrument is attached in front of the handlebar. The combination instrument is divided into 2 function areas.  Indicator lamps ( p. 37)  Display 402644-10...

  • Page 39: Indicator Lamps

    COMBINATION INSTRUMENT Indicator lamps 402646-01 The indicator lamps offer additional information about the operating state of the motorcycle. When the ignition is switched on, all indicator lamps light up briefly except for the turn signal indicator lamp. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The engine warning lamp lights up yellow –...

  • Page 40: Speed

    ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS lamp flashes if the ABS mode "SupMot" is enabled. The TC lamp lights up yellow – The TC or MTC is not available. Contact an authorized KTM workshop. The TC lamp flashes, if TC or MTC actively engage.

  • Page 41: Time

    COMBINATION INSTRUMENT Time  The time is shown in area of the display. The time is displayed in 12 hour format if the language is set to EN-US. Info The time must be reset after the battery was disconnected or the fuse was removed. 402647-13 Temperature ...

  • Page 42: Gear Display

    COMBINATION INSTRUMENT Gear display  The current gear is shown in area of the display. 402647-10 Fuel tank capacity  The fuel tank contents are shown in area of the display. If the fuel level is getting low, the last segment flashes. Refuel at the next opportunity. 402649-10...

  • Page 43: Coolant Temperature Indicator

    COMBINATION INSTRUMENT Coolant temperature indicator The temperature display consists of 8 bars. The more bars that light up, the hotter the coolant. Possible states The engine is cold – the coolant indicator lights up blue. • Engine warm – two to six bars light up. •...

  • Page 44: Trip 1

    COMBINATION INSTRUMENT 7.10 "Trip 1" – Press the UP or DOWN button until the "Trip 1" menu appears on the display. "Trip 1" shows the distance since the last reset, such as between two refueling stops. "Trip 1" runs continuously and counts the distance up to 999. "AVG 1"...

  • Page 45: General Info

    COMBINATION INSTRUMENT 7.12 "General info" – Press the UP or DOWN button until the "General Info" menu appears on the display. "Air Temp" displays the ambient air temperature. "Date" displays the date. "ODO" displays the total distance covered. "Battery" displays the battery voltage. "Time"...

  • Page 46: Settings

    COMBINATION INSTRUMENT 7.14 "Settings" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Pressing the SET button opens the menu. Settings for units or various values are made in the "Settings" menu. Several functions can be enabled or disabled.

  • Page 47: Tc/Abs

    COMBINATION INSTRUMENT 7.16 "TC/ABS" Condition Standard model Warning Voiding of the government approval for road use and the insurance coverage If the ABS is switched off completely, the vehicle's approval for road use is invali- dated. – Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off completely.

  • Page 48: Mtc/Abs

    COMBINATION INSTRUMENT 7.17 "MTC/ABS" Condition R model Warning Voiding of the government approval for road use and the insurance coverage If the ABS is switched off completely, the vehicle's approval for road use is invali- dated. – Only operate the vehicle in closed-off areas remote from public road traffic if the ABS is switched off completely.

  • Page 49: Language

    COMBINATION INSTRUMENT 7.18 "Language" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Pressing the SET button opens the menu. – Press the SET button again to select the language. The menu languages are US English, UK English, German, Italian, French, and Spanish.

  • Page 50: Temp

    COMBINATION INSTRUMENT 7.20 "Temp" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Pressing the SET button opens the menu. – Press the UP or DOWN button until the "Temp" menu is marked on the display. Pressing the SET button again sets the unit of measure.

  • Page 51: Volume

    COMBINATION INSTRUMENT 7.22 "Volume" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Pressing the SET button opens the menu. – Press the UP or DOWN button until the "Volume" menu is marked on the display. Press- ing the SET button again sets the unit of measure.

  • Page 52: Shift Light

    COMBINATION INSTRUMENT – Press the UP or DOWN button until the current day is set. – Press the SET button. The month next to "Date" flashes. – Press the UP or DOWN button until the current month is set. – Press the SET button.

  • Page 53: Extra Functions

    COMBINATION INSTRUMENT 7.25 "Extra functions" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Pressing the SET button opens the menu. – Press the UP or DOWN button until the "Extra functions" menu is marked on the display. –...

  • Page 54: 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 Non-approved or non-recommended tires and wheels impact the handling characteristic. – Only use tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 55: 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 and Warranty Booklet at vehicle handover.

  • Page 56: Loading The Vehicle

    PREPARING FOR USE – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 57 PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 58: 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 59: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 60: Starting Off

    RIDING INSTRUCTIONS Info Do not press the electric starter button until the combination instrument func- tion check 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 61 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 Falling off of the passenger.
  • Page 62 Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If unusual noises arise during operation, stop immediately, switch off the engine, park the vehicle properly, and contact an autho- rized KTM workshop.
  • Page 63 RIDING INSTRUCTIONS – Shift into a higher gear when conditions allow (incline, road situation, etc.). – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info You can see the positions of the 6 forward gears in the figure. The neutral or idle position is between the first and second gears.

  • Page 64: Engine Braking Control (Msr)

    RIDING INSTRUCTIONS Engine braking control (MSR) (Duke) The MSR is an optional auxiliary function of the engine control. If the engine braking effect is too great, the MSR prevents the rear wheel from locking. To avoid slip of the rear wheel, the MSR only opens the throttle valve as far as abso- lutely necessary.

  • Page 65: Applying The Brakes

    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 66: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Very forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents Locking of the wheels due to braking action of the engine. – Pull the clutch during emergency braking, full brake application and when braking on a slippery surface. –...
  • Page 67 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. Note Material damage The vehicle may be damaged by incorrect procedure when parking.

  • Page 68: Transport

    RIDING INSTRUCTIONS – Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to the position and turning it to the posi- tion . To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key. Transport Note Danger of damage The parked vehicle may roll away or fall over.

  • Page 69: Refueling

    – 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 70 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 30) –  Fill the fuel tank with fuel up to the lower edge of the filler neck. Total fuel tank 14 l (3.7 US gal) Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 71: Service Schedule

    Every 20,000 km (12,400 mi) Every 10,000 km (6,200 mi) After 1,000 km (620 mi) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ● Check that the electrical system is functioning properly. ○...
  • Page 72 ● Check the CO adjustment using the KTM diagnostics tool. ○ ● ● ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet.

  • Page 73: Recommended Work

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval 10.3 Recommended work Every four years Every year Every 10,000 km (6,200 mi) After 1,000 km (620 mi) ● Checking the swingarm bearing for play. ● Check the wheel bearing for play. ○...

  • Page 74: Tuning The Chassis

    TUNING THE CHASSIS 11.1 Fork/shock absorber (Duke R) 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 .

  • Page 75: Adjusting The Rebound Damping Of The Fork (Duke R)

    TUNING THE CHASSIS Guideline Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.3 Adjusting the rebound damping of the fork (Duke R) Info The hydraulic rebound damping determines the fork suspension behavior.

  • Page 76: Compression Damping Of The Shock Absorber (Duke R)

    Adjusting the high-speed compression damping of the shock absorber (Duke R) 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.)

  • Page 77: Adjusting The Low-Speed Compression Damping Of The Shock Absorber (Duke R)

    Adjusting the low-speed compression damping of the shock absorber (Duke R) 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.)

  • Page 78: Adjusting The Rebound Damping Of The Shock Absorber (Duke R)

    Adjusting the rebound damping of the shock absorber (Duke R) 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.)

  • Page 79: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screw  clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks V00073-10 Full payload 10 clicks...
  • Page 80 TUNING THE CHASSIS – Raise the motorcycle with the work stand. – Remove the main silencer. – Remove the shock absorber. Main work (Duke) –  Adjust the spring preload by turning adjuster Guideline Spring preload Standard 4 clicks Hook wrench (T106S) V00044-10 Info The spring preload can be set to 10 different positions.

  • Page 81: Adjusting The Footrests

    TUNING THE CHASSIS Finishing work (Duke R) – Install the shock absorber. – Install the main silencer. – Remove the motorcycle from the work stand. – Install the footrest bracket. 11.9 Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides. –...
  • Page 82 TUNING THE CHASSIS – Remove screws  V00045-10 – Adjust the footrest bracket to the desired position. V00051-01 –  Mount and tighten screws Guideline Screw, front footrest bracket M8 25 Nm Loctite ® 243™ (18.4 lbf ft) V00045-10...
  • Page 83 TUNING THE CHASSIS – Mount the rider footrest with the spring and pin. H00385-01 –  Mount lock ring H00384-10...

  • Page 84: Adjusting Foot Brake Lever Stub (Duke R)

    TUNING THE CHASSIS 11.10 Adjusting foot brake lever stub (Duke R) –  Remove screw and take off foot brake lever stub. –  Position foot brake lever stub at desired hole Guideline Standard Front hole –  Mount and tighten screw Guideline Screw, foot brake lever stub 10 Nm...

  • Page 85: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the supports of the lifting gear. –...

  • Page 86: Lifting The Motorcycle With The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. –  Remove the rear lifting gear and lean the vehicle on side stand 402029-10 12.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle may roll away or fall over. –...

  • Page 87: Taking The Motorcycle From The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS – Raise the motorcycle at the front. 12.4 Taking the motorcycle from the front lifting gear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. –...

  • Page 88: Removing The Passenger Seat

    SERVICE WORK ON THE CHASSIS 12.5 Removing the passenger seat –  Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the passenger seat, push it towards the rear, and remove it upward. –...

  • Page 89: Removing The Passenger Seat Cover (Duke R)

    SERVICE WORK ON THE CHASSIS 12.7 Removing the passenger seat cover (Duke R) –  Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the passenger seat cover, push it toward the rear, and remove it upward.

  • Page 90: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 12.9 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 88) 400678-01 12.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 91: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 83) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –...
  • Page 92 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 83) Main work – Shift gear to neutral. – Push the chain upwards near the vertical rib of the swingarm and measure the chain tension ...

  • Page 93: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12.12 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.
  • Page 94 SERVICE WORK ON THE CHASSIS Main work –  Loosen nut – Loosen nuts  –  Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 mm (0.2 in)  Turn the adjusting screws on the left and right so that the markings on the ...

  • Page 95: Checking The Chain, Rear Sprocket, And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 12.13 Checking the chain, rear sprocket, and engine sprocket Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 83) Main work – Check the rear sprocket and engine sprocket for wear. »...
  • Page 96 SERVICE WORK ON THE CHASSIS – Shift gear to neutral. –  Pull the lower chain section with the specified weight Guideline Weight of chain wear measurement 15 kg (33 lb.) –  Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even.

  • Page 97: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. »   If in area by the chain sliding guard screw is visible from above: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 98: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw  K00354-10 12.15 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid can cause skin irritation on contact. –...
  • Page 99 SERVICE WORK ON THE CHASSIS Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

  • Page 100: Brake System

    Only use spare parts on the brake system which have been approved and recom- mended by KTM. 0 0 1 – Only use tires/wheels approved by KTM with the corresponding speed index. – Maintain the specified tire air pressure. –...
  • Page 101 BRAKE SYSTEM Warning Danger of accidents Vehicle rollover – It is not always possible to prevent vehicle rollover in extreme riding situations (e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your driving ability.

  • Page 102: Adjusting The Basic Position Of The Hand Brake Lever

    Do not make any adjustments while riding. V00047-11 13.3 Checking the brake discs Warning 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.)

  • Page 103: Checking The Brake Fluid Level Of The Front Brake

    If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your autho- rized KTM workshop will be glad to help.)
  • Page 104 BRAKE SYSTEM Warning Danger of accidents Reduced braking efficiency due to 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.) (Duke) –...

  • Page 105: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to 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 106 BRAKE SYSTEM Preparatory work – Check the front brake linings. ( p. 105) Main work (Duke) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. –  Remove screws –   Remove cover with membrane –...

  • Page 107: Checking The Front Brake Linings

    Checking the front brake linings 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. –...

  • Page 108: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13.7 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.

  • Page 109: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 13.8 Adjusting the basic position of the foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.
  • Page 110 BRAKE SYSTEM Guideline Nut, push rod, foot brake lever 6 Nm (4.4 lbf ft) –  Mount and tighten screw Guideline Loctite ® 243™ Screw, ball joint of push 10 Nm rod on foot brake cylinder (7.4 lbf ft) – ...

  • Page 111: Checking Rear Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to 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.)

  • Page 112: Adding Rear Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to 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.)
  • Page 113 BRAKE SYSTEM 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. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 114: Checking The Rear Brake Linings

    Checking the rear brake linings 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. –...

  • Page 115: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 83) – Lift the motorcycle with the front lifting gear. ( p. 84) Main work (Duke) –   Remove screw and pull wheel speed sensor out of the hole.

  • Page 116: Installing The Front Wheel

    WHEELS, TIRES – Loosen screw  by several rotations. –  Loosen screws –  Press on screw to push the wheel spindle out of the axle clamp. –  Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs. –...
  • Page 117 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the front wheel bearing. –   Clean and grease shaft seal rings and mating surfaces of the spacers. Long-life grease ( p.
  • Page 118 WHEELS, TIRES (Duke) –   Position wheel speed sensor in the drill hole. Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake caliper. The brake linings are correctly positioned. – Position spacers ...

  • Page 119: Removing The Rear Wheel

    WHEELS, TIRES – Tighten screws  Guideline Screw, front brake caliper M10x1.25 45 Nm Loctite ® 243™ (33.2 lbf ft) – Remove the locking piece of the hand brake lever. – Take the motorcycle from the front lifting gear. ( p.
  • Page 120 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- ton. –   Remove screw and pull wheel speed sensor out of the hole. –  ...

  • Page 121: Installing The Rear Wheel

    WHEELS, TIRES Warning Danger of accidents Reduced braking efficiency due to damaged brake disc. – Always lay the wheel down in such a way that the brake disc is not damaged. – Take the rear wheel out of the swingarm. Info Do not operate the foot brake lever when the rear wheel is removed.
  • Page 122 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Remove spacer. –   Clean and grease shaft seal ring and contact surface of the spacer.
  • Page 123 WHEELS, TIRES – Engage the thurst bearing of brake caliper support  and the swingarm. – Lift the rear wheel into the swingarm, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Place the chain on the sprocket. –...

  • Page 124: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES 14.5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub become damaged. Preparatory work –...

  • Page 125: 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 126 DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regard- less of the actual state of wear.

  • Page 127: Checking The Tire Pressure

    WHEELS, TIRES 14.7 Checking the tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximum tire service life. – Remove the protection cap. – Check the tire pressure when the tires are cold. Tire air pressure, solo Front 2.0 bar (29 psi)

  • Page 128: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 129 ELECTRICAL SYSTEM – Remove positive terminal cover  –  Disconnect both positive cables from the battery. –  Detach rubber band – Pull the battery up and out of the battery holder. K00446-10...

  • Page 130: Installing The Battery

    ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Position the battery in the battery holder. Battery (CBTX9-BS) ( p. 181) The battery terminals face opposite the direction of travel. – Reconnect rubber band  –  Connect both positive cables to the battery.

  • Page 131: Recharging The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
  • Page 132 ELECTRICAL SYSTEM 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. Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the battery.
  • Page 133 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info ...

  • Page 134: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. The main fuse is under the passenger seat. Preparatory work –...
  • Page 135 ELECTRICAL SYSTEM – Remove the faulty main fuse  Info  A defective fuse is indicated by a burned-out fuse wire  A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p.

  • Page 136: Changing The Abs Fuses

    ELECTRICAL SYSTEM 15.5 Changing the ABS fuses Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS.

  • Page 137: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM To change the fuse of the ABS return pump: –  Remove the protection cap and fuse – Insert a new fuse. Fuse (58011109125) ( p. 181) – Mount the protection cap. K00363-10 Finishing work – Mount the passenger seat. ( p.
  • Page 138 ELECTRICAL SYSTEM – Open fuse box cover  K00365-10 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, EFI control unit, alarm system (optional), turn signal Fuse 2 - 10 A - ignition, EFI control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light...
  • Page 139 ELECTRICAL SYSTEM Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

  • Page 140: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15.7 Removing the headlight mask with the headlight Preparatory work – Switch off the ignition by turning the ignition key to the position Main work (Duke) –  Remove screws –  Remove screws K00439-10 (Duke R) – ...

  • Page 141: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Fold the headlight mask forward. –  Disconnect plug-in connectors – Remove the headlight mask. V00075-10 15.8 Installing the headlight mask with the headlight Main work –  Connect plug-in connectors V00075-11...
  • Page 142 ELECTRICAL SYSTEM (Duke) – Position the headlight mask. –  Mount and tighten screws Guideline Screw, headlight EJOT 2 Nm (1.5 lbf ft) –  Mount and tighten screws Guideline Remaining screws, chassis 5 Nm (3.7 lbf ft) K00439-11 – Check that the lighting is functioning properly.

  • Page 143: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15.9 Changing the headlight bulb Note Damage to reflector Reduced brightness. – 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. Preparatory work –...
  • Page 144 ELECTRICAL SYSTEM – Detach retaining clamp  –  Remove bulb – Position the new bulb in the headlight housing. Headlight (H4 / socket P43t) ( p. 182) Tabs engage in the recesses. –  Attach retaining clamp K00438-10 – ...
  • Page 145 ELECTRICAL SYSTEM – Detach retaining clamp  –  Remove bulb – Position the new bulb in the headlight housing. Headlight (H4 / socket P43t) ( p. 182) Tabs engage in the recesses. –  Attach retaining clamp K00442-10 – ...

  • Page 146: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM 15.10 Changing the parking light bulb Note Damage to reflector Reduced brightness. – 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 147: Changing The Turn Signal Bulb (Duke)

    ELECTRICAL SYSTEM 15.11 Changing the turn signal bulb (Duke) Note Damage to reflector Reduced brightness. – 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 148: Checking The Headlight Setting

    ELECTRICAL SYSTEM 15.12 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. –  Make another mark at a distance under the first mark.

  • Page 149: Diagnostics Connector

    ELECTRICAL SYSTEM Main work –  Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking the headlight setting).

  • Page 150: Cooling System

    COOLING SYSTEM 16.1 Cooling system  Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in   radiator cap . Heat expansion causes excess coolant to flow into compensating tank When the temperature falls, this surplus coolant is sucked back into the cooling system.
  • Page 151 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.

  • Page 152: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM Info Do not start up the motorcycle! – Fill/bleed the cooling system. p. 153) – Mount cap  of the compensating tank. – Check the coolant level in the radiator. The radiator must be filled completely. » If the coolant level does not match the specified value: –...
  • Page 153 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.

  • Page 154: Draining The Coolant

    COOLING SYSTEM 16.4 Draining the coolant 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 155: Filling/Bleeding The Cooling System

    COOLING SYSTEM 16.5 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician.
  • Page 156 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 157: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...
  • Page 158 TUNING THE ENGINE – Clean gear teeth  of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gear- ing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.

  • Page 159: Drive Mode (Optional)

    TUNING THE ENGINE – Tighten nut  , holding threaded rod  Guideline Shift rods, nut M6LH 6 Nm (4.4 lbf ft) 17.3 Drive Mode (optional) Possible states SPORT – Homologated performance with very direct response; the traction control • allows greater slip on the rear wheel STREET –...

  • Page 160: Motorcycle Traction Control (Optional) (Mtc)

    TUNING THE ENGINE 17.4 Motorcycle traction control (optional) (MTC) The motorcycle traction control (MTC) lowers the engine torque in case of loss of traction in the rear wheel. Depending on the motorcycle traction control setting, a slight slip on the rear wheel may be desirable.

  • Page 161: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 162 SERVICE WORK ON THE ENGINE Info Drain the engine oil while the engine is at operating temperature. Main work – Rest the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove oil filler plug ...
  • Page 163 SERVICE WORK ON THE ENGINE – Remove screws  . Remove oil filter cover  with the O-ring. –  Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Thoroughly clean the parts and sealing surface. K00371-10 –...
  • Page 164 SERVICE WORK ON THE ENGINE – Remove screw plug  with oil screen  and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing surface. K00373-10 –   Remove screw plug with oil screen and the O-rings.
  • Page 165 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug  with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) K00370-11 – Position the oil screen with the O-rings. –  Mount and tighten screw plug with the O-ring.

  • Page 166: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Mount and tighten oil filler plug  with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 167 SERVICE WORK ON THE ENGINE – Mount and tighten oil filler plug  with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 168: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 169 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the closure of the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys- tem.

  • Page 170: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE – Lubricate the ignition/steering lock. Universal oil spray ( p. 194) 19.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt.

  • Page 171: Storage

    0… 35 °C (32… 95 °F) direct sunshine. – 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 lifting gear. ( p. 83)

  • Page 172: Preparing For Use After Storage

    STORAGE – Lift the motorcycle with the front lifting gear. ( p. 84) – 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 173: Troubleshooting

    Connect the plug-in connection of the fuel line. connection is not connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Throttle opened while starting When starting, DO NOT open the throttle –...
  • Page 174 Check the radiator fan system. – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – N The idle indicator lamp does not Gear position sensor not programmed...
  • Page 175 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 159) – Engine oil too thin (low viscosity) Change the engine oil and oil filter and clean the oil screens. p.

  • Page 176: Technical Data

    TECHNICAL DATA 22.1 engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 692.7 cm³ (42.271 cu in) Stroke 80 mm (3.15 in) Bore 105 mm (4.13 in) Compression ratio 12.7:1 Control OHC, intake with cam levers, exhaust controlled by rocker arm, chain drive Valve diameter, intake 42 mm (1.65 in) Valve diameter, exhaust...

  • Page 177: Engine Tightening Torques

    TECHNICAL DATA 1st gear 14:35 2nd gear 16:28 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 Inside spark plug NGK LKAR9BI‑10...
  • Page 178 TECHNICAL DATA – Remaining screws, engine 6 Nm (4.4 lbf ft) – Screw, clutch spring M5x25 6 Nm (4.4 lbf ft) – Screw, cover plate for oil return line 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, gear position sensor M5x14 5 Nm (3.7 lbf ft) –...
  • Page 179 TECHNICAL DATA Screw, ignition pulse generator 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, locking lever 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil pump cover, bottom 10 Nm (7.4 lbf ft) Loctite ® 243™ Loctite ® 243™...
  • Page 180 TECHNICAL DATA Cylinder head screw Tightening sequence: Lubricated with engine oil Tighten diagonally, beginning with the rear screw on the timing chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft) –...

  • Page 181: Capacities

    TECHNICAL DATA Nut, engine sprocket M20x1.5 80 Nm (59 lbf ft) Loctite ® 243™ Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite ® 243™ – Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft)

  • Page 182: Chassis

    TECHNICAL DATA 22.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork (Duke) WP Performance Systems Up Side Down 4357 Fork (Duke R) WP Performance Systems 4357 ROTA SPLIT Shock absorber (Duke) WP Performance Systems emulsion with Pro‑Lever linkage WP Performance Systems 4618 with Pro‑Lever linkage Shock absorber (Duke R) Suspension travel (Duke)

  • Page 183: Electrical System

    TECHNICAL DATA 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) Rear 2.2 bar (32 psi) Secondary drive ratio 16:40 Chain 5/8 x 1/4” (520) X‑ring Steering head angle 63.5°...

  • Page 184: Tires

    Rear tires 120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL Metzeler SPORTEC M7 RR Metzeler SPORTEC M7 RR Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 Duke Fork part number 05.18.7L.19...

  • Page 185: Duke R

    TECHNICAL DATA Medium (standard) 6.0 N/mm (34.3 lb/in) Fork length 816 mm (32.13 in) Fork oil per fork leg 480 ml (16.23 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 191) 22.7.2 Duke R Fork part number 05.18.8M.11 WP Performance Systems 4357 ROTA SPLIT Fork Compression damping Comfort...

  • Page 186: Shock Absorber

    TECHNICAL DATA 22.8 Shock absorber 22.8.1 Duke Shock absorber article number 01.18.7N.19 Shock absorber WP Performance Systems emulsion with Pro‑Lever linkage Spring preload Standard 4 clicks Static sag 20 mm (0.79 in) Riding sag 45 mm (1.77 in) Fitted length 364 mm (14.33 in) 22.8.2 Duke R...

  • Page 187: Chassis Tightening Torques

    TECHNICAL DATA Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 11 mm (0.43 in) Spring rate Soft 70 N/mm (400 lb/in) Medium (standard) 75 N/mm (428 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag...
  • Page 188 TECHNICAL DATA – Screw, combination instrument 4 Nm (3 lbf ft) – Screw, combination switch, left 3.5 Nm (2.58 lbf ft) – Screw, combination switch, right 3.5 Nm (2.58 lbf ft) Loctite ® 243™ Screw, foot brake lever stub (Duke) 6 Nm (4.4 lbf ft) –...
  • Page 189 TECHNICAL DATA Screw, foot brake lever stub (Duke R) 10 Nm (7.4 lbf ft) Loctite ® 243™ – Screw, fuel pump 6 Nm (4.4 lbf ft) – Screw, fuel spoiler 3 Nm (2.2 lbf ft) – Screw, lower radiator bracket 5 Nm (3.7 lbf ft) Screw, magnetic holder on side stand 5 Nm (3.7 lbf ft)
  • Page 190 TECHNICAL DATA Screw, handrail M8x30 Countersunk screw Loctite ® 243™ 18 Nm (13.3 lbf ft) Screw, handrail, cover M8x20 18 Nm (13.3 lbf ft) Loctite ® 243™ Screw, ignition lock (tamper-proof Loctite ® 243™ screw) Screw, license plate holder 18 Nm (13.3 lbf ft) Loctite ®...
  • Page 191 TECHNICAL DATA Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft) Loctite ® 243™ – Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) – Nut, frame to linkage lever M14x1.5 100 Nm (73.8 lbf ft) – Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) –...

  • Page 192: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 193 SUBSTANCES – 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. Synthetic engine oil Recommended supplier Motorex ® – Cross Power 4T Engine oil (SAE 10W/50) Standard/classification –...
  • Page 194 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 195) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding proper- ties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 195: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
  • Page 196 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 197: 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 198: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Motor Slip Regulation Auxiliary function of the motor control, which prevents rear wheel locking with excessive engine braking effect, by lightly opening the throttle valve Motorcycle Traction Control Auxiliary function of the motor control, which reduces engine...

  • Page 199: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 200: List Of Symbols

    ABS warning lamp lights up yellow – Status or error messages relating to ABS. The ABS lamp flashes if the ABS mode "SupMot" is enabled. The TC lamp lights up yellow – The TC or MTC is not available. Contact an authorized KTM workshop. The TC lamp flashes, if TC or MTC actively engage.
  • Page 201 LIST OF SYMBOLS The idling speed indicator lamp lights up green – The transmission has shifted to idle. The high beam indicator lamp lights up blue – The high beam is switched on.

  • Page 202: Index

    INDEX INDEX Brakes, applying ....... . . 63 ABS ......... 98 Capacity Accessories .
  • Page 203 INDEX gear display ....... . . 40 Customer service ....... . 15 "General info"...
  • Page 204 INDEX free travel, checking ......106 Headlight setting adjusting ........146 Foot brake lever stub checking .
  • Page 205 INDEX MTC ........158 Rear hub rubber dampers checking .
  • Page 206 INDEX spring preload, adjusting ......77 Tire condition checking ........123 Shock absorber article number .
  • Page 207 *3213397en* 3213397en 02/2016 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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