KTM 690 Duke 2017 Owner's Manual
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KTM 690 Duke 2017 Owner's Manual

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OWNER'S MANUAL
2017
690 Duke
690 Duke R
Art. no. 3213549en

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Summary of Contents for KTM 690 Duke 2017

  • Page 1 OWNER'S MANUAL 2017 690 Duke 690 Duke R Art. no. 3213549en...
  • 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 Fork part number ..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Shock absorber article number ......22 Symbols used ............7 CONTROLS..............24 Formats used............8 Clutch lever............24 SAFETY ADVICE.............. 9 Hand brake lever..........24 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS Time..............39 RIDING INSTRUCTIONS..........56 Temperature............39 Performing checks and vehicle care when preparing for use..........56 Gear display ............40 Starting............. 57 Fuel tank capacity..........40 Starting off............58 Coolant temperature indicator ......41 Shifting, riding ..........58 "Favorites"...
  • Page 7 TABLE OF CONTENTS 11.8 Adjusting the spring pretension of the shock 13.5 Adding front brake fluid ........ 103 absorber ............78 13.6 Checking the front brake linings ......105 11.9 Adjusting the footrests........79 13.7 Checking the free travel of foot brake lever ..106 11.10 Adjusting foot brake lever stub (Duke R) ....
  • Page 8 TABLE OF CONTENTS 15.11 Changing the turn signal bulb (Duke) ....146 22 TECHNICAL DATA............178 15.12 Checking the headlight setting ......147 22.1 Engine ............178 15.13 Adjusting the headlight range......147 22.2 Engine tightening torques ......... 179 15.14 Diagnostics connector ........148 22.3 Capacities ............

  • 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

    – Always wear protective clothing that is in good condition and meets the legal regulations. 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. The tools are not contained in the vehicle but can be ordered under the number in parenthe- ses.

  • 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) V00574-10...
  • Page 19 VIEW OF VEHICLE Clutch lever ( p. 24) Seat Passenger seat Handrails ( p. 33) Seat lock ( p. 32) Side stand ( p. 35) Shift lever ( p. 34) Engine number ( p. 21)

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

    VIEW OF VEHICLE View of vehicle, rear right (example) V00575-10...
  • 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. H01128-10...

  • Page 23: Key Number

    SERIAL NUMBERS 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. 402241-10 Engine number The engine number is located on the left side of the engine under the engine sprocket. 401949-10...

  • Page 24: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 402295-10 Shock absorber article number (Duke) Shock absorber article number is on the left side of the shock absorber. 402382-10...
  • Page 25 SERIAL NUMBERS (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. V00554-10 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) V00555-10 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. Button is the SET 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 The 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. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 33: Closing The Filler Cap

    CONTROLS – Lift cover of the filler cap and insert the ignition key in the lock. Note Danger of damage Ignition key breakage. – To take pressure off of the ignition key, push down on the filler cap. Damaged igni- tion keys must be replaced. –...

  • Page 34: Seat Lock

    CONTROLS Seat lock The seat lock is located on the left side of the vehicle. It can be locked with the ignition key. V00043-10 Tool set The tool set is located under the passenger seat. K00414-10...

  • Page 35: Handrails

    CONTROLS 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 6.11 Passenger footrest The passenger footrests are foldable. Possible states Passenger footrest folded in – For operation without a passenger. •...

  • Page 36: Shift Lever

    CONTROLS 6.12 Shift lever The shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11...

  • Page 37: Foot Brake Lever

    CONTROLS 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 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.

  • Page 38: Combination Instrument

    COMBINATION INSTRUMENT Combination instrument 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 The current ambient temperature is shown in area...

  • 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

    Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel. 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 Guideline Maximum engine speed During the first: 1,000 km (620 mi) 6,000 rpm After the first: 1,000 km (620 mi) 7,800 rpm – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. –...
  • Page 57 PREPARING FOR USE Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. Check that your baggage is fixed properly at regular intervals.

  • 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 death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Note Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.

  • 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 A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.

  • 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 The rear wheel can lock due to the engine braking effect. – Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground. –...
  • Page 67 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down. –...

  • Page 68: Transport

    RIDING INSTRUCTIONS – Swing the side stand forward with your foot as far as it will go and lean the vehicle on it. – 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 .

  • 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. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 70 RIDING INSTRUCTIONS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open the filler cap. ( p.

  • Page 71: Service Schedule

    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 30,000 km (18,600 mi) every 10,000 km (6,200 mi) after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ● ●...

  • 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)

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 77 TUNING THE CHASSIS Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. – Using an open end wrench, turn adjusting screw clockwise all the way. Info Do not loosen fitting – Turn counterclockwise by the number of turns corresponding to the shock absorber type.

  • Page 78: Adjusting The Low-Speed Compression Damping Of The Shock Absorber (Duke R)

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 79: Adjusting The Rebound Damping Of The Shock Absorber (Duke R)

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 80: Adjusting The Spring Pretension Of The Shock Absorber

    TUNING THE CHASSIS 11.8 Adjusting the spring pretension of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring pretension defines the initial status of the spring operation on the shock absorber.

  • Page 81: Adjusting The Footrests

    TUNING THE CHASSIS Info The spring pretension can be set to 10 different positions. (Duke R) – Measure and note down the spring length in the preloaded condition. – Loosen retaining ring and adjusting ring with the special tool. Hook wrench (T106S) Hook wrench (T157S) –...
  • Page 82 TUNING THE CHASSIS – Remove lock ring – Remove the pin of the rider footrest. Take off the rider footrest with the spring. V00562-10 – Remove screws V00045-10 – Adjust the footrest bracket to the desired position. V00051-01...
  • Page 83 TUNING THE CHASSIS – Mount and tighten screws Guideline Screw, front footrest bracket M8 25 Nm Loctite ® 243™ (18.4 lbf ft) V00045-10 – Mount the rider footrest with the spring and pin. H00385-01 – Mount lock ring V00562-10...

  • 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 Loctite...

  • 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 can roll away or fall over. – Park the vehicle on a firm and level 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 can 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 can roll away or fall over. – Park the vehicle on a firm and level 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. – Remove the ignition key from the seat lock.

  • 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 the road 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 Info The upper chain section...

  • Page 93: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12.12 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly.
  • 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 left and right chain adjusters are in the same position relative to the reference marks...

  • 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 causes skin irritation. – Keep brake fluid out of the reach of children.
  • 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. V00554-11 13.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (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, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 104 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) (Duke) –...

  • Page 105: Adding Front Brake Fluid

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 106 BRAKE SYSTEM 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. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 107: Checking The Front Brake Linings

    Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.

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

    BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. – Check the brake linings for damage and cracking. »...

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

    BRAKE SYSTEM (Duke R) – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3…...
  • Page 110 BRAKE SYSTEM Info The range of adjustment is limited. – Turn ball joint as required until free travel is reached. If necessary, adjust the basic position of the foot brake lever. Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) –...
  • Page 111 BRAKE SYSTEM (Duke R) – Disconnect spring – Loosen nut and screw in push rod until you have maximum free travel. V00568-10 – To adjust the basic position of the foot brake lever to individual requirements, loosen nut and turn screw accordingly.

  • Page 112: Checking Rear Brake Fluid Level

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.

  • Page 113: Adding Rear Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 114 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 115: Checking The Rear Brake Linings

    Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.

  • Page 116: 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 117 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. – Always lay the wheel down in such a way that the brake discs are not dam- 602546-10 aged.

  • Page 118: Installing The Front Wheel

    WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...
  • Page 119 WHEELS, TIRES Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) (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.
  • Page 120 WHEELS, TIRES (Duke R) – 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 121: Removing The Rear Wheel

    WHEELS, TIRES – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) K00434-10 14.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the rear lifting gear.
  • Page 122 WHEELS, TIRES – Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward. M00666-10 – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. Info Cover the components to protect them against damage. –...

  • Page 123: Installing The Rear Wheel

    WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
  • Page 124 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 125: 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 126: Checking The Tire Condition

    Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
  • Page 127 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 128: 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 129: 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 130 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. V00578-10...

  • Page 131: Installing The Battery

    ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Position the battery in the battery holder. Alternative 1 Battery (YTX9-BS) ( p. 185) Alternative 2 Battery (HTZ12A-BS) ( p. 185) The battery terminals face opposite the direction of travel. – Reconnect rubber band –...

  • Page 132: Recharging The Battery

    ELECTRICAL SYSTEM – Connect negative cable to the battery. Guideline Screw, battery terminal 2 Nm (1.5 lbf ft) V00580-11 Finishing work – Mount the passenger seat. ( p. 86) – Set the time and date. ( p. 49) 15.3 Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns.
  • Page 133 ELECTRICAL SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regula- tions. 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 134 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 Never remove lid –...

  • Page 135: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not 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 136 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. 186) V00582-10 Insert a new spare fuse into the starter relay to have it available when needed.

  • Page 137: Changing The Abs Fuses

    ELECTRICAL SYSTEM 15.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not 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 138: 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. 186) – Mount the protection cap. V00583-10 Finishing work – Mount the passenger seat. ( p.
  • Page 139 ELECTRICAL SYSTEM – Open fuse box cover K00365-10 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, engine electronics control unit, alarm system (optional), turn signal Fuse 2 - 10 A - ignition, engine electronics control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light...
  • Page 140 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 186) Fuse (75011088015) ( p.

  • Page 141: 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) – Remove screws –...

  • Page 142: 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 143 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. (Duke R) –...

  • Page 144: 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 145 ELECTRICAL SYSTEM – Detach retaining clamp – Remove bulb – Position the new bulb in the headlight housing. Headlight (H4 / socket P43t) ( p. 186) Tabs engage in the recesses. – Attach retaining clamp K00438-10 – Mount protection cap –...
  • Page 146 ELECTRICAL SYSTEM – Detach retaining clamp – Remove bulb – Position the new bulb in the headlight housing. Headlight (H4 / socket P43t) ( p. 186) Tabs engage in the recesses. – Attach retaining clamp K00442-10 – Mount protection cap –...

  • Page 147: 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 148: 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 149: 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 150: 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 151: 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 152: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM 16.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at oper- ating temperature.
  • Page 153 COOLING SYSTEM Main work – Remove radiator cap and cap of the compensating tank. – Check the antifreeze in the coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze in the coolant does not match the specified value: –...

  • Page 154: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM » If you had to add more coolant than the specified amount: > 0.50 l (> 0.53 qt.) – Fill/bleed the cooling system. p. 155) – Mount radiator cap 16.3 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
  • Page 155 COOLING SYSTEM Preparatory work – Park the motorcycle on a horizontal surface. Main work – Check the coolant level in compensating tank The coolant level must be at the MIN marking. » If the coolant in the compensating tank is not at the required level, but the tank is not empty: –...

  • Page 156: 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 open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at oper- ating temperature.

  • Page 157: Filling/Bleeding The Cooling System

    COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the engine. – Remove screw – Remove the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Plug, drain hole of water pump M10x1 15 Nm K00379-10...
  • Page 158 COOLING SYSTEM – Remove radiator cap V00077-10 – Remove bleeder screw – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw immediately. Coolant 1.20 l (1.27 qt.) Coolant (...
  • Page 159 COOLING SYSTEM – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Check the coolant level in the compensating tank. ( p. 152)

  • Page 160: 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 161 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 162: Drive Mode (Optional)

    TUNING THE ENGINE – Tighten nut while 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 163: 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 164: 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 165 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 with the O-ring from the clutch cover.
  • Page 166 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 – Remove screws .
  • Page 167 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. V00589-10 – Remove screw plug with oil screen and the O-rings. –...
  • Page 168 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. Guideline Plug, oil screen M20x1.5...

  • Page 169: 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 death. – Always make sure there is sufficient ventilation when running the engine. –...
  • Page 170 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 death. – Always make sure there is sufficient ventilation when running the engine. –...

  • Page 171: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 172 CLEANING, CARE – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p.

  • Page 173: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Preserving materials for paints, metal and rubber ( p. 198) – Treat all painted parts with a mild paint polish. Perfect Finish and high gloss polish for paints ( p. 198) Info Do not polish parts that were matte when delivered as this would strongly impair the material quality.
  • Page 174 CLEANING, CARE – Clean the motorcycle. ( p. 169) – Clean the brake system. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.

  • Page 175: 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 176: 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 177: 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 178 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 179 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 162) – Engine oil too thin (low viscosity) Change the engine oil and oil filter and clean the oil screens. p.

  • Page 180: 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 181: 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, 300 W Spark plug Inside spark plug NGK LKAR9BI‑10...
  • Page 182 TECHNICAL DATA – Remaining screws, engine 6 Nm (4.4 lbf ft) Screw, axial lock of camshaft 6 Nm (4.4 lbf ft) Loctite ® 243™ – Screw, clutch spring 6 Nm (4.4 lbf ft) – Screw, cover plate for oil return line 6 Nm (4.4 lbf ft) Screw, gear sensor 5 Nm (3.7 lbf ft)
  • Page 183 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 184 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 185: 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 186: 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 187: 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 188: 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 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...

  • Page 189: Fork

    TECHNICAL DATA 22.7 Fork 22.7.1 Duke Fork part number 05.18.7L.19 Fork WP Performance Systems Up Side Down 4357 Spring rate 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.

  • Page 190: Shock Absorber

    TECHNICAL DATA Spring rate Medium (standard) 6.5 N/mm (37.1 lb/in) Air chamber length 80±20 mm (3.15±0.79 in) Fork length 831 mm (32.72 in) Fork oil per fork leg 534 ml (18.05 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 196) 22.8 Shock absorber 22.8.1...
  • Page 191 TECHNICAL DATA Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 11 mm (0.43 in) Spring rate Soft 70 N/mm (400 lb/in)

  • Page 192: Chassis Tightening Torques

    TECHNICAL DATA 22.9 Chassis tightening torques – Screw, headlight EJOT 2 Nm (1.5 lbf ft) Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite ® 243™ – Remaining screws, chassis 5 Nm (3.7 lbf ft) – Retaining clamp, brake line 3 Nm (2.2 lbf ft) –...
  • Page 193 TECHNICAL DATA – Screw, battery terminal 2 Nm (1.5 lbf ft) – Screw, brake assembly 5 Nm (3.7 lbf ft) – Screw, brake fluid reservoir of rear brake 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, chain guard 4 Nm (3 lbf ft) Screw, chain sliding guard 10 Nm (7.4 lbf ft) Loctite...
  • Page 194 TECHNICAL DATA – Screw, bottom triple clamp 12 Nm (8.9 lbf ft) – Screw, foot brake lever (Duke R) 20 Nm (14.8 lbf ft) Screw, footrest bracket, rear M8x30 25 Nm (18.4 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, footrest bracket, rear M8x50 25 Nm (18.4 lbf ft)
  • Page 195 TECHNICAL DATA – Remaining screws, chassis 45 Nm (33.2 lbf ft) – Screw, foot brake lever (Duke) 25 Nm (18.4 lbf ft) – Screw, handlebar support 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, side stand 35 Nm (25.8 lbf ft) Screw, subframe 45 Nm (33.2 lbf ft) Loctite...

  • Page 196: 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 197 JASO T903 MA ( p. 199) – SAE ( p. 199) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Synthetic engine oil...
  • Page 198 SUBSTANCES Recommended supplier Motorex ® – Power Synt 4T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 199) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding proper- ties.

  • Page 199: 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 200 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 201: Standards

    STANDARDS JASO T903 MA Different technical development directions required a separate 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 specifica- tion.

  • Page 202: 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 203: 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 204: 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 205 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 206: Index

    INDEX INDEX Brakes, applying ....... . . 63 ABS ......... 98 Capacity Accessories .
  • Page 207 INDEX gear display ....... . . 40 Customer service ....... . 15 "General info"...
  • Page 208 INDEX free travel, checking ......106 Headlight setting adjusting ........147 Foot brake lever stub checking .
  • Page 209 INDEX MSR ......... 62 MTC .
  • Page 210 INDEX spring pretension, adjusting ..... . 78 Tire condition checking ........124 Shock absorber article number .
  • Page 211 *3213549en* 3213549en 10/2016 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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