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

2013
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2013
OWNER'S MANUAL
690 Duke EU
690 Duke AUS/UK
690 Duke MAL
690 Duke R EU
690 Duke R AUS/UK
690 Duke R MAL
Art. no. 3211953en

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Summary of Contents for KTM 690 DUKE EU

  • Page 1 2013 OWNER'S MANUAL 690 Duke EU 690 Duke AUS/UK 690 Duke MAL 690 Duke R EU 690 Duke R AUS/UK 690 Duke R MAL Art. no. 3211953en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 DEAR KTM CUSTOMER KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Shock absorber part number ....... 23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 CONTROLS..............25 Symbols used ............7 Clutch lever............25 Formats used............7 Hand brake lever..........25 SAFETY ADVICE.............. 8 Throttle grip ............26 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS 6.13 Closing the filler cap .......... 40 10.4 Compression damping of the shock absorber..68 6.14 Seat lock............41 10.5 Adjusting the high-speed compression damping of the shock absorber (Duke R) ......68 6.15 Tool set............. 41 10.6 Adjusting the low-speed compression damping of 6.16...
  • Page 7 TABLE OF CONTENTS 11.15 Checking/rectifying the fluid level of the 14.5 Changing the ABS fuses ........123 hydraulic clutch..........88 14.6 Changing the fuses of individual power 12 BRAKE SYSTEM ............89 consumers............124 12.1 ABS/antilock brake system........89 14.7 Removing the headlight mask with the headlight............
  • Page 8 TABLE OF CONTENTS 18 CLEANING, CARE ............152 INDEX ................190 18.1 Cleaning the motorcycle ........152 18.2 Checks and maintenance steps for winter operation............154 19 STORAGE ..............155 19.1 Storage ............155 19.2 Preparing for use after storage......156 20 TROUBLESHOOTING ..........

  • 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: 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 11: Degrees Of Risk And Symbols

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

  • Page 12: 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 13: Protective Clothing

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

  • Page 14: 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 15: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 16: Figures

    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 side (example) C00298-10...
  • Page 19 VIEW OF VEHICLE Clutch lever ( p. 25) Seat Passenger seat Handrails ( p. 42) Seat lock ( p. 41) Engine number ( p. 22) Shift lever ( p. 43) Side stand ( p. 46)

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

    VIEW OF VEHICLE View of vehicle, rear right side (example) C00299-10...
  • Page 21 VIEW OF VEHICLE Tool set ( p. 41) Map‑Select switch Light switch ( p. 27) Headlight flasher switch ( p. 28) Turn signal switch ( p. 28) Horn button ( p. 27) Filler cap Ignition/steering lock ( p. 30) Emergency OFF switch ( p.

  • Page 22: Serial Numbers

    602542-10 Type label (690 Duke EU, 690 Duke MAL, 690 Duke R EU, 690 Duke R MAL) The type label is located on the right side of the frame. C00301-10...

  • Page 23: Key Number

    SERIAL NUMBERS (690 Duke AUS/UK, 690 Duke R AUS/UK) The type label is located on the left side of the frame. 602549-10 Key number can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 24: Engine Number

    SERIAL NUMBERS Engine number (Duke) The engine number is located on the left side of the engine under the engine sprocket. C00302-10 (Duke R) The engine number is located on the left side of the engine under the engine sprocket. 602550-10...

  • Page 25: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. C00303-10 Shock absorber part number (Duke) The shock absorber part number is on the left side of the shock absorber. C00304-10...
  • Page 26 SERIAL NUMBERS (Duke R) The shock absorber part number is found on the damper at the rear. 602551-10...

  • Page 27: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00305-10 Hand brake lever (Duke) The hand brake lever is fitted on the right side of the handlebar. 602570-10...

  • Page 28: 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. 602552-10 Throttle grip The throttle grip is fitted on the right side of the handlebar. B00922-10...

  • Page 29: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button C00308-11 Light switch The light switch is fitted on the left side of the handlebar.

  • Page 30: Headlight Flasher Switch

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

  • Page 31: Emergency Off Switch

    CONTROLS Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is inter- rupted, a running engine stops, and the engine cannot be started. Emergency OFF switch on –...

  • Page 32: Ignition/Steering Lock

    CONTROLS 6.10 Ignition/steering lock The ignition/steering lock is located in front of the upper triple clamp. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

  • Page 33: Function Buttons

    CONTROLS 6.11.2 function buttons You can change the display mode with the MODE button Possible display modes are the odometer (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2), and gear display (GEAr). Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- tion (TRIP 2) to 0.0.

  • Page 34: Combination Instrument - Indicator Lamps

    CONTROLS 6.11.4 Combination instrument - indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up green –...

  • Page 35: Display

    CONTROLS 6.11.5 Display When you switch on the ignition, all display segments light up for one second as a function check. 400836-01 LEnGth Following the display function check, the LEnGth wheel circumference is shown for one sec- ond. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series pro- duction tire.

  • Page 36: Speed Display

    CONTROLS 6.11.6 Speed display is shown in kilometers per hour km/h or in miles per hour mph. The speed 401443-10 6.11.7 Setting kilometers or miles Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary.

  • Page 37: Time

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

  • Page 38: 6.11.10 Odo Display

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

  • Page 39: Setting/Resetting Display Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 401445-01 6.11.12 Setting/resetting display TRIP 2 Info...

  • Page 40: 6.11.13 Trip F Display

    CONTROLS 6.11.13 TRIP F display If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 401447-01 6.11.14 GEAr display In display mode GEAr, the gear currently engaged is displayed.

  • Page 41: 6.11.15 Coolant Temperature Indicator

    CONTROLS 6.11.15 Coolant temperature indicator The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up. Possible states Engine cold –...

  • Page 42: Closing The Filler Cap

    CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Lift cover of the filler cap and insert the ignition key in the lock. Note Danger of damage Ignition key breakage.

  • Page 43: Seat Lock

    CONTROLS 6.14 Seat lock The seat lock is located on the left side of the vehicle. It can be locked with the ignition key. B00928-10 6.15 Tool set The tool set is located under the passenger seat. B00929-10...

  • Page 44: Handrails

    CONTROLS 6.16 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. 602579-10 6.17 Passenger footrests The passenger footrests can be folded up and down. Possible states Passenger footrests folded up –...

  • Page 45: Shift Lever

    CONTROLS 6.18 Shift lever (Duke) The shift lever is mounted on the left side of the engine. 602555-11 (Duke R) The shift lever is mounted on the left side of the engine. 602554-11...
  • Page 46 CONTROLS (Duke) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 602555-10 (Duke R) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 602554-10...

  • Page 47: Foot Brake Lever

    CONTROLS 6.19 Foot brake lever (Duke) Foot brake lever is located in front of the right footrest. C00313-10 (Duke R) Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 602556-10...

  • Page 48: Side Stand

    CONTROLS 6.20 Side stand (Duke) The side stand is located on the left side of the vehicle. C00312-10 (Duke R) The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use.

  • Page 49: Preparing For Use

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

  • Page 50: Running In The Engine

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

  • Page 51: Loading The Vehicle

    PREPARING FOR USE – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 52 PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 53: 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 54: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 55 Take the weight off the side stand and swing it back up with your foot as far as it will Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous.

  • Page 56: Starting Off

    RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 57 RIDING INSTRUCTIONS Warning Danger of accidents Danger of accidents caused by dangerous driving. – Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on. Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured.
  • Page 58 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If unusual noises arise during operation, stop immediately, park the vehicle properly, and contact an authorized KTM workshop. (Duke) –...
  • Page 59 RIDING INSTRUCTIONS (Duke R) – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch, and open the throttle. Info You can see the positions of the 6 forward gears in the figure.

  • Page 60: Applying The Brakes

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 61 RIDING INSTRUCTIONS Warning Danger of accidents Greater stopping distance due to ABS. – Braking should be appropriate to the driving situation and the road conditions. Warning Danger of accidents Excessively forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents Locking of the wheels due to braking action of the engine.

  • Page 62: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the vehicle, lock the steering and remove the ignition key. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.

  • Page 63: Transport

    RIDING INSTRUCTIONS – Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine with the ignition key - the emergency OFF switch is intended for emergencies only.

  • Page 64: Refueling

    Material damage Premature clogging of the fuel filter. – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.)
  • Page 65 RIDING INSTRUCTIONS – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. –...

  • Page 66: Service Schedule

    K10N K100A K200A Check the functioning of the electrical equipment. • • • Read out the fault memory using the KTM diagnostics tool. • • • Check the measured service values with the KTM diagnostics tool. • • Change the engine oil and filter, clean the oil screens.
  • Page 67 • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record. K10N: Once after 1,000 km (621.4 mi)

  • Page 68: Tuning The Chassis

    TUNING THE CHASSIS 10.1 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 69: 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. 10.3 Adjusting the rebound damping of the fork (Duke R) Info The hydraulic rebound damping determines the fork suspension behavior.

  • Page 70: Compression Damping Of The Shock Absorber

    Adjusting the high-speed compression damping of the shock absorber (Duke R) Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 71: Adjusting The Low-Speed Compression Damping Of The Shock Absorber (Duke R)

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

  • Page 72: Adjusting The Rebound Damping Of The Shock Absorber (Duke R)

    Adjusting the rebound damping of the shock absorber (Duke R) Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 73: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 602574-10 Full payload 10 clicks...
  • Page 74 TUNING THE CHASSIS – Remove the main silencer. – Remove the shock absorber. Main work (Duke) – Adjust the spring preload by turning adjustment unit Guideline Spring preload Standard 4 clicks Hook wrench (T106S) B00936-10 Info The spring preload can be set to 10 different positions. (Duke R) –...

  • Page 75: Adjusting The Footrests

    TUNING THE CHASSIS Finishing work (Duke R) – Install the shock absorber. – Install the main silencer. – Remove the motorcycle from the work stand. 10.9 Adjusting the footrests – Remove lock ring – Remove the pin of the rider's footrest. Take off the rider's footrest with the spring. C00329-10 –...
  • Page 76 TUNING THE CHASSIS – Adjust the footrest bracket to the desired position. C00331-01 – Mount and tighten screws Guideline Screw, front footrest bracket M8 25 Nm Loctite ® 243™ (18.4 lbf ft) C00330-10 – Mount the rider's footrest with the spring and pin. C00332-01...
  • Page 77 TUNING THE CHASSIS – Mount lock ring – Repeat the operations on the opposite side. C00329-10...

  • Page 78: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Mount the support of the wheel stand. –...

  • Page 79: Raising The Motorcycle With The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand. C00312-11 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. –...

  • Page 80: Taking The Motorcycle Off Of The Front Wheel Stand

    SERVICE WORK ON THE CHASSIS – Raise the front of the motorcycle. 11.4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. –...

  • Page 81: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS 11.6 Mounting the passenger seat – Hook catches of the passenger seat onto the storage compartment, lower the rear, and simultaneously push forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 82: Mounting The Passenger Seat Cover (Duke R)

    SERVICE WORK ON THE CHASSIS 11.8 Mounting the passenger seat cover (Duke R) Warning Danger of accidents Accident risk caused by the presence of a passenger. – If the passenger seat cover is mounted, the vehicle is not suitable for transporting a passenger. Do not ride with a passenger. –...

  • Page 83: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11.10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 84: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

  • Page 85: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.12 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.
  • Page 86 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks...

  • Page 87: Checking The Chain, Rear Sprocket And Engine Sprocket

    SERVICE WORK ON THE CHASSIS 11.13 Checking the chain, rear sprocket and engine sprocket – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 88 SERVICE WORK ON THE CHASSIS – Shift gear to neutral. – Pull the lower chain section with specified weight Guideline Weight of chain wear measurement 15 kg (33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even.

  • Page 89: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If drill hole becomes visible on the chain sliding guard in area – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 90: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11.15 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 91: Brake System

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.

  • Page 92: Adjusting The Basic Position Of The Hand Brake Lever

    BRAKE SYSTEM ABS warning lamp must light up after the ignition is switched on and go out after start- ing off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled and the wheels may lock during braking.

  • Page 93: Checking The Brake Discs

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

  • Page 94: Checking The Brake Fluid Level Of The Front Brake

    KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) (Duke) –...

  • Page 95: Adding Front Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 96 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 97: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 98: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM (Duke) – 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 99: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM (Duke) – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) »...
  • Page 100 BRAKE SYSTEM (Duke) – Disconnect spring – Remove screw – Loosen nut and turn it back with ball joint until the maximum amount of free travel is reached. – To adjust the basic position of the foot brake lever to individual requirements, loosen nut and turn screw accordingly.
  • Page 101 BRAKE SYSTEM (Duke R) – Disconnect spring – Loosen nut and screw in push rod until you have maximum free travel. 602581-10 – To adjust the basic position of the foot brake lever to individual requirements, loosen nut and turn screw accordingly.

  • Page 102: Checking Rear Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 103: Adding Rear Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 104 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 105: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 106: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 76) – Raise the motorcycle with the front wheel stand. ( p. 77) Main work (Duke) – Remove screw and pull wheel speed sensor out of the hole.

  • Page 107: Installing The Front Wheel

    WHEELS, TIRES – Loosen screws – Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs. –...
  • Page 108 WHEELS, TIRES – Clean screw and wheel spindle – Lift the front wheel into the fork, position it, and insert the wheel spindle. The arrow on the spoke points in the direction of motion. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm...
  • Page 109 WHEELS, TIRES (Duke R) – Insert wheel speed sensor into the hole. Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake caliper and check that the brake linings are seated correctly. – Position spacers .

  • Page 110: Removing The Rear Wheel

    WHEELS, TIRES 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 76) Main work – Remove screw and pull wheel speed sensor out of the hole. – Remove nut . Remove chain adjuster 602563-10 –...

  • Page 111: Installing The Rear Wheel

    WHEELS, TIRES – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. – Withdraw the wheel spindle. – Pull the rear wheel back until the brake caliper support is suspended freely between the brake disc and rim.
  • Page 112 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Remove bushing . Clean and grease the mating surfaces of the bushings and the shaft seal rings.
  • Page 113 WHEELS, TIRES – Engage the counter bearing of the brake caliper support and swingarm. Carefully lift the rear wheel into the swingarm and engage the brake disc. Lay the chain on the rear sprocket and mount the wheel spindle. – Mount chain adjuster and nut Info...

  • Page 114: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES 13.5 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 will be damaged. Preparatory work –...

  • Page 115: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
  • Page 116 DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.

  • Page 117: Checking The Tire Pressure

    WHEELS, TIRES 13.7 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 118: Electrical System

    ELECTRICAL SYSTEM 14.1 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 119: Installing The Battery

    ELECTRICAL SYSTEM – Remove positive terminal cover – Disconnect the positive cable of the battery. – Detach rubber band – Pull the battery up and out of the battery holder. B00963-10 14.2 Installing the battery Main work – Position the battery in the battery holder. Info The terminals of the battery must face in the direction of travel.

  • Page 120: Recharging The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
  • Page 121 ELECTRICAL SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are very important for the service life of the battery.
  • Page 122 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 123: Changing The Main Fuse

    ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass 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 124 ELECTRICAL SYSTEM – Remove the faulty main fuse Info A defective fuse is indicated by a burned-out fuse wire A reserve fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p. 174) 602588-10 Insert a new replacement fuse into the starter relay to have it available when needed.

  • Page 125: Changing The Abs Fuses

    ELECTRICAL SYSTEM 14.5 Changing the ABS fuses Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass 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 126: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM To change the fuse of the ABS return pump: – Take off the protection cover and remove fuse – Insert a new fuse. Fuse (58011109125) ( p. 174) – Mount the protection cover. B00966-11 Finishing work – Mount the passenger seat. ( p.
  • Page 127 ELECTRICAL SYSTEM – Open fuse box cover B00968-10 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, clock, EFI control unit, alarm sys- tem (optional) Fuse 2 - 10 A - ignition, combination instrument, EFI control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light, turn signal, alarm system (optional)
  • Page 128 ELECTRICAL SYSTEM Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

  • Page 129: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 14.7 Removing the headlight mask with the headlight Preparatory work – Switch off all power consumers and switch off the engine. Main work (Duke) – Remove screws B00972-10 (Duke R) – Remove screws 602577-10...

  • Page 130: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Fold the headlight mask forward. – Disconnect plug – Set down the headlight mask. 602578-11 14.8 Refitting the headlight mask with the headlight Main work – Plug in connector 602578-10...

  • Page 131: Changing The Headlight Bulb

    ELECTRICAL SYSTEM (Duke) – Position the headlight mask. – Mount and tighten screws Guideline Screw, headlight EJOT 2 Nm (1.5 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) – Check that the lighting is functioning properly. B00972-11 (Duke R) –...
  • Page 132 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 127) Main work – Disconnect connector – Take off protection cap B00973-10 – Detach retaining clamp –...

  • Page 133: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM – Mount protection cap – Plug in connector B00973-10 Finishing work – Refit the headlight mask with the headlight. ( p. 128) – Check the headlight setting. ( p. 133) 14.10 Changing the parking light bulb Note Damage to reflector Reduced brightness. –...

  • Page 134: Changing The Turn Signal Bulb (Duke)

    ELECTRICAL SYSTEM Main work – Pull cable sleeve and the socket of parking light carefully out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W / socket W2.1x9.5d) ( p. 174) –...

  • Page 135: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Remove the screw on the rear of the turn signal housing. – Remove turn signal glass – Press the bulb carefully into the socket, turn it counterclockwise by about 30°, and pull it out of the socket. Info Do not touch the reflector with your fingers, and keep it free from grease.

  • Page 136: Adjusting The Headlight Range

    ELECTRICAL SYSTEM – Check the headlight setting. The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: –...

  • Page 137: Cooling System

    COOLING SYSTEM 15.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radi- ator cap . The heat expansion causes the surplus coolant to flow into the compensating tank .
  • Page 138 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 139: Checking The Coolant Level In The Compensating Tank

    COOLING SYSTEM » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! – Fill/bleed the cooling system. p. 140) – Mount cap of the compensating tank. –...
  • Page 140 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 141: Draining The Coolant

    COOLING SYSTEM Info Do not start up the motorcycle! – Fill/bleed the cooling system. p. 140) 15.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 142: Filling/Bleeding The Cooling System

    COOLING SYSTEM – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw . Remove the radiator cap. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Plug, drain hole of water pump M10x1 15 Nm...
  • Page 143 COOLING SYSTEM – 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. Alternative 1 Coolant ( p. 183) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 144: Tuning The Engine

    TUNING THE ENGINE 16.1 Setting the engine characteristics Preparatory work – Switch off the ignition by turning the ignition key to the position – Remove the passenger seat. ( p. 78) Main work – Pull off the Map‑Select switch with holder from the retaining bracket.

  • Page 145: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16.2 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
  • Page 146 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 147 TUNING THE ENGINE – Tighten nut , holding the threaded rod Guideline Shift rods, nut M6LH 6 Nm (4.4 lbf ft)

  • Page 148: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. Condition The engine is at operating temperature. – Stand the motorcycle upright on a horizontal surface. –...
  • Page 149 SERVICE WORK ON THE ENGINE Info Drain the engine oil only when the engine is warm. Main work – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring.
  • Page 150 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. B00990-10 –...
  • Page 151 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 area. B00993-10 – Position the oil screen with the O-rings. – Mount and tighten screw plug with the O-ring.
  • Page 152 SERVICE WORK ON THE ENGINE Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil.

  • Page 153: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil.

  • Page 154: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 155 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the closure of the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys- tem.

  • Page 156: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 18.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 157: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 76) –...

  • Page 158: Preparing For Use After Storage

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

  • Page 159: Troubleshooting

    Coupling of fuel hose connection not Reconnect coupling of fuel hose connection. 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 160 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 161 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 146) – Engine oil too thin (low viscosity) Change the engine oil and filter, clean the oil screens. p. 146) –...

  • Page 162: Blink Code

    BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code of FI warning lamp (MIL) 09 FI warning lamp (MIL) flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high...
  • Page 163 BLINK CODE Blink code of FI warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Error level condition Rollover sensor - input signal too low Rollover sensor - input signal too high Blink code of FI warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short Error level condition...
  • Page 164 BLINK CODE Blink code of FI warning lamp (MIL) 27 FI warning lamp (MIL) flashes 2x long, 7x short Error level condition SVCC circuit - tracking error Blink code of FI warning lamp (MIL) 33 FI warning lamp (MIL) flashes 3x long, 3x short Error level condition Injector cylinder 1 - circuit fault Blink code of FI warning...
  • Page 165 BLINK CODE Blink code of FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code of FI warning lamp (MIL) 65 FI warning lamp (MIL) flashes 6x long, 5x short...
  • Page 166 BLINK CODE Blink code of FI warning lamp (MIL) 85 FI warning lamp (MIL) flashes 8x long, 5x short Error level condition Accelerator position sensor circuit A - input signal too low Accelerator position sensor circuit A - input signal too high Blink code of FI warning lamp (MIL) 86 FI warning lamp (MIL) flashes 8x long, 6x short...
  • Page 167 BLINK CODE Blink code of FI warning lamp (MIL) 90 FI warning lamp (MIL) flashes 9x long Error level condition DBW throttle actuator control internal motor - stuck in inactive DBW throttle actuator control internal motor - stuck in active Blink code of FI warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short...
  • Page 168 BLINK CODE Blink code of FI warning lamp (MIL) 96 FI warning lamp (MIL) flashes 9x long, 6x short Error level condition System voltage - input signal too low System voltage - input signal too high...

  • Page 169: Technical Data

    TECHNICAL DATA 22.1 engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.6:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)

  • Page 170: Engine Tightening Torques

    TECHNICAL DATA 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug Inside spark plug NGK LKAR8BI-9 Outside spark plug NGK LMAR7A-9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling...
  • Page 171 TECHNICAL DATA – Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) ® Screw, oil pump cover, top 6 Nm (4.4 lbf ft) Loctite 243™ – Chain securing guide 5 Nm (3.7 lbf ft) ® Cylinder head screw M6x25 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 172 TECHNICAL DATA ® Screw, stator 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, thermostat case M6x20 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, timing chain guide rail M6x30 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, timing chain tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite...

  • Page 173: Capacities

    TECHNICAL DATA – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug outside M10x1 11 Nm (8.1 lbf ft) – Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) head...

  • Page 174: Coolant

    TECHNICAL DATA 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 183) Coolant (mixed ready to use) ( p. 183) 22.3.3 Fuel Total fuel tank capacity, approx. 14 l (3.7 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.
  • Page 175 TECHNICAL DATA Brake discs - diameter Front 320 mm (12.6 in) Rear 240 mm (9.45 in) Brake discs - wear limit Front 4.2 mm (0.165 in) Rear 4.5 mm (0.177 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded...

  • Page 176: Electrical System

    TECHNICAL DATA Battery CBTX9-BS Battery voltage: 12 V Nominal capacity: 8 Ah Maintenance-free Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 22.5 Electrical system Headlight H4 / socket P43t 12 V 60/55 W Parking light...

  • Page 177: Tires

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

  • Page 178: Shock Absorber

    TECHNICAL DATA Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring length with preload spacer(s) 303 mm (11.93 in) 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)

  • Page 179: Duke R

    TECHNICAL DATA 22.8.2 Duke R Shock absorber part number 15.18.7M.11 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport...

  • Page 180: Chassis Tightening Torques

    TECHNICAL DATA Soft 70 N/mm (400 lb/in) Medium (standard) 75 N/mm (428 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Riding sag 60… 65 mm (2.36… 2.56 in) Fitted length 370 mm (14.57 in) Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) (...
  • Page 181 TECHNICAL DATA – Screw, plastic clamp of brake line on 2 Nm (1.5 lbf ft) fork leg – Screw, pressure regulator 4 Nm (3 lbf ft) ® Bolt, headlight mask 6.3 Nm (4.65 lbf ft) Loctite 243™ ® Chain guard 4 Nm (3 lbf ft) Loctite 243™...
  • Page 182 TECHNICAL DATA – Shift rods, nut M6LH 6 Nm (4.4 lbf ft) – Main silencer holder (Duke R) M8x40 25 Nm (18.4 lbf ft) – Main silencer holder (Duke R) M8x60 25 Nm (18.4 lbf ft) Nut, manifold on cylinder head 20 Nm (14.8 lbf ft) Copper paste Nut, rear sprocket screw...
  • Page 183 TECHNICAL DATA ® Screw, linkage bracket, front engine fix- 25 Nm (18.4 lbf ft) Loctite 243™ ing arm – Screw, main silencer clamp (Duke R) 15 Nm (11.1 lbf ft) – Screw, main silencer fixation 25 Nm (18.4 lbf ft) ®...
  • Page 184 TECHNICAL DATA – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Screw, steering head M20x1.5 40 Nm (29.5 lbf ft) – Adjusting ring of swingarm bearing M24x1.5 25 Nm (18.4 lbf ft) – Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –...

  • Page 185: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ing properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 186 189) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex ® products. Synthetic engine oil Supplier Motorex ®...
  • Page 187 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® –...
  • Page 188 SUBSTANCES Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 189: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 190 AUXILIARY SUBSTANCES Long-life grease Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline –...

  • Page 191: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
  • Page 192 INDEX Brake system ....... 89-103 INDEX Brakes ........58 ABS .
  • Page 193 INDEX kilometers or miles, setting ..... . 34 Engine oil ODO display ....... . . 36 adding .
  • Page 194 INDEX removing ........104 Fuse Light switch ........27 individual power consumers, changing .
  • Page 195 INDEX Passenger seat Shift lever ........mounting .
  • Page 196 INDEX tires ........175 Throttle grip .
  • Page 197 *3211953en* 3211953en 09/2012 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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