KTM 690 Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 690 Enduro R EU
  6. Owner's manual
KTM 690 Owner's Manual

KTM 690 Owner's Manual

Rally factory replica
Hide thumbs Also See for 690:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
OWNER'S MANUAL
2008
690 Rally Factory Replica
ART. NO. 3211241en

Advertisement

Table of Contents
loading

Related Manuals for KTM 690

Summary of Contents for KTM 690

  • Page 1 OWNER'S MANUAL 2008 690 Rally Factory Replica ART. NO. 3211241en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    LOCATION OF SERIAL NUMBERS ........7 Important maintenance work to be carried out by an Chassis number............... 7 authorized KTM workshop. (as additional order)....28 Type label............... 7 Important checks and maintenance work to be carried Key number ..............7 out by the rider.
  • Page 5 CONTENTS 690 Rally Factory Replica 3 of 3 ........92 Fitting front wheel ............ 51 SUBSTANCES..............96 Removing rear wheel ..........51 AUXILIARY SUBSTANCES..........98 Fitting rear wheel ............52 STANDARDS..............100 Tire condition checking..........53 INDEX ................101 Checking tire air pressure ..........53 Checking spoke tension..........

  • Page 6: 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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important Notes

    You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 8 IMPORTANT NOTES Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death. Warning Danger that will probably lead to severe and permanent injury or death. Note Danger of serious damage to machine or material. Warning Risk of environmental damage.

  • Page 9: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 3 L OCATION OF SERIAL NUMBERS Chassis number Chassis number is embossed in the steering head at the right.  600001-10 Type label Type label is fixed to the right of the steering head.  600001-11 Key number The key number is stamped on the key strap.

  • Page 10: Shock Absorber Part Number

    LOCATION OF SERIAL NUMBERS Shock absorber part number Shock absorber part number is attached at the shock absorber unit, to the rear of  the direction of travel. 600026-10...

  • Page 11: Operating Elements

    OPERATING ELEMENTS 4 O PERATING ELEMENTS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 600006-10 Hand brake lever The hand brake lever is located on the right side of the handlebar and operates the ...

  • Page 12: Light Switch

    OPERATING ELEMENTS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail lights are switched on.

  • Page 13: Speedometer Activation And Test

    OPERATING ELEMENTS Speedometer activation and test 4.11 Activating the speedometer: The speedometer is activated when one of the keys is pressed or an impulse comes from the wheel speed sensor. Display test For the function test of the display, all display segments light up briefly. 400313-01 WS (wheel size) After the function test of the display, the wheel size WS is displayed.

  • Page 14: Setting The Clock

    OPERATING ELEMENTS Setting the clock 4.14 Condition The motorcycle is standing. – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The hour display flashes. –...

  • Page 15: Querying Lap Time

    OPERATING ELEMENTS Querying lap time 4.16 Info This function can be called only if lap times are measured. Condition The motorcycle is standing. – briefly and repeatedly until LAP appears at the bottom right of Press the button the display. –...

  • Page 16: Display Mode Speed / Clk (Time)

    OPERATING ELEMENTS Display mode SPEED / CLK (time) 4.19 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button "+". no function Press the button "‑".

  • Page 17: Display Mode Speed/Tr2 (Trip Master 2)

    OPERATING ELEMENTS Display mode SPEED/TR2 (trip master 2) 4.23 – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button "+" and the button "‑". A very practical function for rides by the road book.

  • Page 18: Display Mode Speed/S1 (Stop Watch 1)

    OPERATING ELEMENTS Display mode SPEED/S1 (stop watch 1) 4.26 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel sensor.

  • Page 19: Fuses

    OPERATING ELEMENTS Overview of conditions and ability to be enabled Display The motorcycle is Menu can be standing enabled Display mode SPEED/LAP (lap time) • Display mode SPEED/ODO (odometer) Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...

  • Page 20: Fuel Tap

    OPERATING ELEMENTS Fuel tap 4.30 The fuel tap is located on the right over the fork pivot.  The fuel tap can be used to control the individual fuel tanks. The fuel tap does not have an OFF position since the fuel pump does not let fuel pass when the engine is stopped.

  • Page 21: Shift Lever

    OPERATING ELEMENTS Shift lever 4.32 The shift lever is mounted on the left side of the engine.  600003-12 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 600003-20 Foot brake pedal 4.33...

  • Page 22: Steering Lock

    OPERATING ELEMENTS Steering lock 4.35 The steering lock is fitted on the left of the steering head.  The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible. 600103-10 Locking the steering 4.36 Note Danger of damage Danger of damage by the vehicle running away or falling over.

  • Page 23: Tips And Hints On Putting Into Operation

    When using your motorcycle, 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 24: Running In The Engine

    TIPS AND HINTS ON PUTTING INTO OPERATION – Do not exceed the overall maximum permitted weight and the axle loads. Specification Maximum permissible overall weight 400 kg (881.84 lb.) Maximum permissible front axle load 190 kg (418.87 lb.) Maximum permissible rear axle load 250 kg (551.15 lb.) –...

  • Page 25: Riding Instructions

    RIDING INSTRUCTIONS 6 R IDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. –...

  • Page 26: Starting Up

    Info First gear is used for starting off or for steep inclines. If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta- neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

  • Page 27: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo- nents to cool down before starting work on them. Note Danger of damage Danger of damage by the vehicle running away or falling over.
  • Page 28 RIDING INSTRUCTIONS – Replace the filler cap and turn clockwise until the tank is tightly closed. Info Run the fuel tank breather hoses without kinks.

  • Page 29: Greasing And Service Table

    GREASING AND SERVICE TABLE 7 G REASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. K05N K15A K45A Engine Change the engine oil and oil filter, and clean the oil screen. ( P. 67) •...

  • Page 30: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    K05N: after 500 km (310.7 mi) K15A: every 1,500 km (932 mi) K45A: every 4,500 km (2,796 mi) T1A: daily Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service. •...

  • Page 31: Maintenance Work On Chassis And Engine

    For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set- tings of the suspension components must match your body weight. – As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Specification Standard rider weight 75…...

  • Page 32: Adjusting Rebound Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw of the Low Speed damping and the High Speed damp-  clockwise until it stops.  – Turn back counterclockwise the number of clicks or turns corresponding to the shock absorber type.

  • Page 33: Checking Static Sag Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking static sag of the shock absorber – Measure distance of rear wheel unloaded. ( P. 30)  – Ask someone to help you by holding the motorcycle upright. – Measure the distance between the rear axle and the fixed point again. 0 0 A –...

  • Page 34: Adjusting Riding Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen screw  0 0 1 0 0 2 – Turn adjusting ring until the spring is no longer under tension.  Combination wrench (50329080000) Hook wrench (T106S) – Measure the overall spring length when not under tension. –...

  • Page 35: Installing Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw  600094-10 – Remove screw  – Remove shock absorber. 600095-10 Installing shock absorber 8.13 – Check parts for damage and wear. Replace damaged or worn parts. – Position the shock absorber. –...

  • Page 36: Checking Basic Setting Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking basic setting of fork 8.14 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller weight differences can be compensated by the spring preload.

  • Page 37: Bleeding Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding fork legs 8.17 – Jack up the motorcycle. ( P. 29) – Remove bleeder screws briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. –...

  • Page 38: Checking Play Of Steering Head Bearing

    Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 39: Fork Offset

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten screw  Specification Screw, top steering stem 20 Nm (14.75 lbf ft) – Fully tighten screw  Specification Screw, top triple clamp 17 Nm (12.54 lbf ft) 600100-12 – Position the steering damper .

  • Page 40: Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE Handlebar position 8.24 On the upper triple clamp, there are 2 holes at a distance of to each other.  Distance between holes 15 mm (0.59 in)  The holes on the handlebar support are placed at a distance of from the center.

  • Page 41: Adjusting The Throttle Cables

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the holding plate with handlebar clamp with intermediate rubber  pieces and elastomers   Elastomer kit green - soft quality (SXS05125203) Elastomer kit yellow - medium quality (standard) (SXS05125204) Elastomer kit red - hard quality (SXS05125205) Info The elastomers are available in different versions.

  • Page 42: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension 8.29 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, bear- ings in transmission and rear wheel) are under additional load.

  • Page 43: Adjusting Basic Setting Of Clutch Lever

    Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately by an authorized KTM workshop. – Check the thickness of the front brake disc at several places on the disc to see if it conforms to measurement ...

  • Page 44: Checking Free Play Of Hand Brake Lever

    Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 45: Topping Up The Front Brake Fluid

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 46: Removing Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 47: Changing The Front Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 48: Checking Rear Brake Disc

    Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately by an authorized KTM workshop. – Check the thickness of the rear brake disc at several places on the disc to see if it conforms to measurement ...

  • Page 49: Checking Rear Brake Fluid Level

    Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –...

  • Page 50: Checking Rear Brake Linings

    Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 51: Mounting Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 52: Removing Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info KTM recommends DOT 5.1 brake fluid from Motorex ® . This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands. Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 53: Fitting Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting front wheel 8.53 Warning Danger of accidents Reduced braking 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 54: Fitting Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the distance bushing  600037-10 – Remove the rear sprocket carrier  600038-10 Fitting rear wheel 8.55 Warning Danger of accidents Reduced braking 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 55: Tire Condition Checking

    Tire condition checking 8.56 Info Fit only tires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

  • Page 56: Checking Spoke Tension

    Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 57: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat 8.61 – Lift the quick-locking clip and rotate in the direction of the arrow.  600047-10 – Carefully push the seat to the rear and remove it. 600048-10 Mounting the seat 8.62 –...

  • Page 58: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Open the quick release of the fuel line on the left and right.  – Remove screws of the left and right halves of the fuel tank.   – Remove the fuel tank on the left and right.

  • Page 59: Lowering The Fuel Tank At The Rear

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Open the quick release of the fuel line  – Remove screw  600092-10 – Fold the rear tank upward in the direction of the arrow and use a belt to secure  it to the handlebar.

  • Page 60: Removing The Motor Guard

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Detach the belt and carefully position the rear tank.  600091-10 – Mount and tighten screw  Specification Screw, rear tank fixing 20 Nm Loctite ® 243™ bracket (14.75 lbf ft) – Clean and connect the quick releases of the fuel line with each other.

  • Page 61: Mounting The Motor Guard

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull the motor guard forward out of the frame.  600074-11 Mounting the motor guard 8.68 – Check parts for damage and wear. Replace damaged or worn parts. – Insert the motor guard into the frame.

  • Page 62: Adjusting The Headlamp

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the headlamp 8.70 – Remove the trim. ( P. 54) – On a light-colored wall in front of which there is a horizontal surface, make a mark 0 0 A at the height of the center of the low beam headlamp. –...

  • Page 63: Installing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery 8.72 – Check parts for damage and wear. Replace damaged or worn parts. – Place the battery in the battery holder.  Battery (YTZ10S) ( P. 80) – Position the retaining bracket .

  • Page 64: Removing The Main Fuse

    Replace a burned-out main fuse only by an equivalent fuse.  – Insert the main fuse. Fuse (58011109130) Info 600108-11 If the new fuse burns out, contact an authorized KTM workshop. – Replace the protection cover. – Mount the seat ( P. 55)

  • Page 65: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the coolant level 8.76 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 66: Removing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the coolant level in the compensating tank  The compensating tank must be half full. » If the level of the cooling liquid does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( P.

  • Page 67: Cleaning Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning air filter 8.80 Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. –...

  • Page 68: Carburetor - Adjusting Idle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - adjusting idle 8.82 – Turn the tap handle of the fuel tap to the R REAR  position. (Figure 600016-10 P. 18) – Remove the front fuel tank. ( P. 55) – Screw in the idle adjusting screw until it stops and then to the prescribed basic ...

  • Page 69: Checking Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking engine oil level 8.83 Info The engine oil level can be checked on a cold or hot engine. – Stand the motorcycle upright on a horizontal surface. Conditions The engine is at operating temperature. –...

  • Page 70: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 8.86 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 71: Cleaning The Oil Screen

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the oil screen 8.87 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 72: Mounting Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting oil filter 8.88 – Check parts for damage and wear. Replace damaged or worn parts. – Insert the oil filter  – Oil the O-ring of the oil filter cover and mount it with the oil filter cover ...

  • Page 73: Topping Up Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil 8.90 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the screw cap on the clutch cover and fill up with engine oil. ...

  • Page 74: Troubleshooting

    Do not touch parts of the ignition system. Have work on the ignition system car- ried out in an authorized KTM workshop. – Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.
  • Page 75 P. 62) – Low external temperature Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop. – Engine does not speed up. Carburetor running over because float Have carburetor checked. needle dirty or worn.

  • Page 76: Cleaning

    CLEANING CLEANING Cleaning motorcycle 10.1 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 electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 77: Storage

    STORAGE STORAGE Storage 11.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 78: Technical Data - Engine

    TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11,8:1 Idle speed 1600… 1700 rpm Control OHC, 4 valves controlled via rocker arm, drive via tooth/wheel chain Valve diameter, intake 40 mm (1.57 in)

  • Page 79: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Plug, oil bore self-tapping 9 Nm (6.64 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ ® Oil jet, conrod lubrication 2 Nm (1.48 lbf ft) Loctite 243™...
  • Page 80 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head Tightening sequence: Engine oil (any) Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 15 Nm (11.06 lbf ft) Step 2 30 Nm (22.13 lbf ft) Step 3 45 Nm (33.19 lbf ft) Step 4...

  • Page 81: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR TECHNICAL DATA - CARBURETOR 690 Rally Factory Replica 14.1 Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4100B Needle position 5 th position from top Idle mixture adjusting screw Open 2 turns Main jet 168 (160)

  • Page 82: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS TECHNICAL DATA - CHASSIS Frame Trellis frame of chromium-molybdenum steel tubes, powder- coated Suspension travel front 300 mm (11.81 in) Rear 310 mm (12.2 in) Fork offset Mark 1 visible 20 mm (0.79 in) No mark 22 mm (0.87 in) Brake system Disc brakes, brake calipers on floating bearings...

  • Page 83: Tires

    Rear tire 90/90 - 21 54 S TT 130/80 - 18 66 S TT Michelin T63 Michelin T63 For further information, see: http://www.ktm.com Capacity - fuel 15.3 Tank capacity Front left half of tank 9 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P.

  • Page 84: Technical Data - Fork

    TECHNICAL DATA - FORK TECHNICAL DATA - FORK Fork part number 14.18.7D.10 Fork WP 4860 MXMA Compression damping Standard 12 clicks Rebound damping Standard 20 clicks Spring length with preload spacer(s) 502 mm (19.76 in) Spring rate 65… 75 kg (143.3… 165.34 lb.) 4.6 N/mm (26.27 lb/in) 75…...

  • Page 85: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7D.17 Shock absorber WP 5018 DACC Compression damping, high-speed Standard 20 turns Compression damping, low-speed Standard 15 clicks Rebound damping Standard 22 clicks Spring preload Standard 14 mm Spring rate 65…...

  • Page 86: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining screws, chassis 4 Nm (2.95 lbf ft) – Screw, fuel tap on frame 5 Nm (3.69 lbf ft) – Screw, brake line on bottom triple 2 Nm (1.48 lbf ft) clamp ®...

  • Page 88: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM 690 Rally Factory Replica 1 of 3 19.1 63,134 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 C_AD/12 -X200 C_BD/12 9 10 11 12 32,33 C_AU/2 C_BI/2 400349-10...
  • Page 89 WIRING DIAGRAM Components: Battery Generator Starter relay with fuse High beam relay Low beam relay Starter motor Radiator fan Voltage regulator/rectifier Gear sensor switch Temperature switch for radiator fan Ignition lock Electric starter button Cable colors: green green green green green green yellow-red...
  • Page 90 WIRING DIAGRAM yellow-blue black-yellow brown brown brown brown black black-red black-red white-green black-green green-red pink orange white-red yellow-blue brown yellow black-orange orange green green...
  • Page 91 WIRING DIAGRAM...

  • Page 92: Rally Factory Replica 2 Of 3

    WIRING DIAGRAM 690 Rally Factory Replica 2 of 3 19.2 400350-10...
  • Page 93 WIRING DIAGRAM Components: CDI controller Throttle valve sensor TPS Temperature sensor for indicator lamp Pulse generator Ignition coil Cable colors: orange brown brown blue yellow black gray black-blue gray black-brown black-yellow black-yellow...
  • Page 94 WIRING DIAGRAM 690 Rally Factory Replica 3 of 3 19.3 -H10 -H11 -H12 C_DI/2 C_CJ/2 C_CJ/2 C_CW/2 C_CW/2 C_CX/2 2.1 2.2 2.1 2.2 2.1 2.2 C_CX/2 C_AK/2 C_CX/2 C_CZ/3 C_DB/4 C_AK/2 C_AK/2 -X404 -X402 -X401 C_CW/2 C_AH/2 C_CY/3 C_DA/4 C_AH/2...
  • Page 95 WIRING DIAGRAM Components: Roadbook not assigned not assigned GPS (optional) Iritrac (optional) Wheel speed sensor Right rear flasher Left front flasher Left rear flasher Right front flasher Brake / tail light Additional rear light (optional) Parking light ICO Light (optional) Roadbook light Low beam High beam...
  • Page 96 WIRING DIAGRAM pink yellow-blue yellow-blue yellow-blue yellow-blue brown brown brown brown brown brown brown yellow-blue orange violet violet violet violet black black black black black black black black green-white brown white black-brown white-yellow white white white brown brown brown brown brown green-gray blue-gray...
  • Page 97 WIRING DIAGRAM white white white brown brown brown brown brown brown brown brown black-yellow black-green brown...
  • Page 98 According to – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the ® corresponding properties. KTM recommends Motorex products. Supplier Motorex – ® Motorex Hydraulic Fluid 75 Brake fluid DOT 5.1...
  • Page 99 SAE ( P. 100) (SAE 20W/60) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- ® sponding properties. KTM recommends Motorex products. Synthetic engine oil Supplier Motorex –...
  • Page 100 AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Universal oil spray Specification – ® KTM recommends Motorex products. Supplier Motorex – ® Motorex Joker 440 Universal Chain cleaner Specification – ® KTM recommends Motorex products. Supplier Motorex – ® Motorex Chain Clean 611 Offroad chain spray Specification –...
  • Page 101 AUXILIARY SUBSTANCES High-luster polish for paint Specification – ® KTM recommends Motorex products. Supplier Motorex – ® Motorex Moto Polish Contact spray Specification – ® KTM recommends Motorex products. Supplier Motorex – ® Motorex Accu Contact...
  • Page 102 STANDARDS STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, 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 and ATV engines.With most motorcycles and ATVs, the gearbox and the clutch are lubricated with the same oil as the engine.
  • Page 103 INDEX INDEX Dust boots Air filter cleaning ....... . . 35 cleaning .
  • Page 104 INDEX Horn ........10 removing .
  • Page 105 *3211241en* 3211241en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

Table of Contents