KTM 690 DUKE EU 2009 Owner's Manual
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KTM 690 DUKE EU 2009 Owner's Manual

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OWNER'S MANUAL
2009
690 DUKE EU
690 DUKE AUS/UK
690 DUKE JP
ART. NO. 3211370en

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Summary of Contents for KTM 690 DUKE EU 2009

  • Page 1 OWNER'S MANUAL 2009 690 DUKE EU 690 DUKE AUS/UK 690 DUKE JP ART. NO. 3211370en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you DEAR KTM CUSTOMER enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 Reproduction, even in part, 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

    CONTENTS Setting the clock .............. 28 CONTENTS MEANS OF REPRESENTATION ..........6 Combination instrument - display ODO ....... 29 IMPORTANT NOTES ............... 7 Combination instrument - setting/resetting TRIP 1....29 VIEW OF VEHICLE..............12 Combination instrument - setting/resetting TRIP 2....30 View of vehicle, front left side..........
  • Page 6 Important maintenance work to be carried out by an Adding rear brake fluid ..........76 authorized KTM workshop. (as additional order)....55 Checking the rear brake linings .......... 77 MAINTENANCE WORK ON CHASSIS AND ENGINE ....56 Removing front wheel ..........
  • Page 7 CONTENTS Checking the low beam headlight adjustment....110 STORAGE ................145 Checking the high beam headlight adjustment ....111 Storage................145 Adjusting the light range of the low beam headlight ... 112 Putting into operation after storage ........146 Adjusting the light range of the high beam headlight ..113 TECHNICAL DATA - ENGINE ..........

  • Page 8: Means Of Representation

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

  • Page 9: Important Notes

    Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth- erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 10 Spare parts, accessories In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 11 IMPORTANT NOTES Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.
  • Page 12 IMPORTANT NOTES Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that will possibly lead to light injury if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side 700132-01...
  • Page 15 VIEW OF VEHICLE Combination instrument Rear mirror Clutch lever Seat Handrail Front brake caliper Left fuel tap Shift lever Engine number Side stand...

  • Page 16: View Of Vehicle, Rear Right

    VIEW OF VEHICLE View of vehicle, rear right 700133-01...
  • Page 17 VIEW OF VEHICLE Seat lock Light switch, headlight flasher switch, indicator switch, horn button Filler cap Emergency OFF switch, electric starter button Hand brake lever Chassis number, type label Rear brake caliper Passenger footrests Map‑Select switch Foot brake pedal Level viewer, engine oil Right fuel tap...

  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number/type label The chassis number is stamped on the right of the steering head.  The type label is on the right of the frame behind the steering head.  500006-01 Key number The key number can be found on the KEYCODECARD.

  • Page 19: Engine Number

    LOCATION OF SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket.  700125-01 Fork part number The fork part number is stamped on the inner side of the fork stub. ...

  • Page 20: Shock Absorber Part Number

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

  • Page 21: Controls

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

  • Page 22: Light Switch

    CONTROLS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

  • Page 23: Flasher Switch

    CONTROLS Flasher switch The flasher switch is fitted on the left side of the handlebar.  Possible states Flasher light off Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. Flasher light, right, on –...

  • Page 24: Ignition/Steering Lock

    CONTROLS Ignition/steering lock The ignition/steering lock is 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 25: Electric Starter Button

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

  • Page 26: Combination Instrument - Function Buttons

    CONTROLS Combination instrument - function buttons 5.11 You can change the display mode with the MODE button  Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas- ter 2 (TRIP 2). Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- ...

  • Page 27: Combination Instrument - Indicator Lamps

    CONTROLS Combination instrument - indicator lamps 5.13 The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The flasher indicator lamp flashes green simultaneously with the flashers – Flasher light is switched on. The idle speed indicator lamp lights up green – The transmission is switched to idle.

  • Page 28: Combination Instrument - Display

    CONTROLS Combination instrument - display 5.14 When you switch on the ignition, all display segments light up for a second as a function test. 700118-01 LEnGTth Following the display function test, the wheel circumference LEnGth is shown for one sec- ond.

  • Page 29: Combination Instrument - Speedometer

    CONTROLS Combination instrument - speedometer 5.15 The speed is shown in kilometers per hour km/h or in miles per hour Mph.  700114-01 Setting kilometers or miles 5.16 Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country.

  • Page 30: Combination Instrument - Time

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

  • Page 31: Combination Instrument - Display Odo

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

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

    CONTROLS – Switch on the ignition by turning the ignition key to the position – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 700121-01 Combination instrument - setting/resetting TRIP 2 5.21...

  • Page 33: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.22 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 Parallel to the TRIP F display, the fuel warning light switches on. 700123-01 Combination instrument - coolant temperature indicator 5.23...

  • Page 34: Opening Filler Cap

    CONTROLS Opening filler cap 5.24 – Lift the cover of the filler cap and insert the ignition key.  – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 500023-10 Closing filler cap 5.25...

  • Page 35: Fuel Taps

    CONTROLS Fuel taps 5.26 The fuel taps are located on the left/right under the fuel tank.  Possible states Fuel supply closed – The knurled screws are turned clockwise as far as possible. The • level cannot be compensated and no fuel can flow out of the fuel tank. Fuel tap open –...

  • Page 36: Seat Lock

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

  • Page 37: Tool Set

    CONTROLS Tool set 5.30 The tool set is located in the storage compartment under the seat.  700134-01 Passenger footrests 5.31 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. •...

  • Page 38: Shift Lever

    CONTROLS Shift lever 5.32 The shift lever is mounted on the left side of the engine.  700137-01 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 700138-01...

  • Page 39: Foot Brake Pedal

    CONTROLS Foot brake pedal 5.33 The footbrake pedal is located in front of the right footrest.  The footbrake pedal operates the rear brake. 700136-01 Side stand 5.34 The side stand is coupled with the safety electric starter system - see the riding instruc- ...

  • Page 40: General Tips And Hints On Putting Into Operation

    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 characteristics 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 41: 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 42: Loading The Vehicle

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Loading the vehicle Warning Danger of accidents Unstable riding behavior. – 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 43 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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 44: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( p.

  • Page 45: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space without an effective exhaust extraction system.
  • Page 46 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to the position After you switch on the ignition, you can hear the fuel pump working for about 2 seconds.

  • Page 47: Starting Up

    RIDING INSTRUCTIONS Starting up – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 48 RIDING INSTRUCTIONS 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. Warning Danger of accidents Reduced road grip with new tires. –...
  • Page 49 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 50: Braking

    Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Brake system failure. –...

  • Page 51: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by brak- ing.
  • Page 52 RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components get very hot when the machine is driven. – Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run.

  • Page 53: Refueling

    RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
  • Page 54 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 32) – Fill the fuel tank with fuel up to measurement  Guideline Level 50 mm (1.97 in)  Total fuel tank 13.5 l Super unleaded (ROZ 95 / RON 95 / capacity, approx.

  • Page 55: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A Engine • • • • • Change the engine oil and filter, clean the oil screens. p. 126) • • Check and adjust valve clearance.
  • Page 56 SERVICE SCHEDULE K10N K50A K100A Attachments Check the headlamp setting. • • • • • Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • • Brakes Check the front brake linings. ( p.

  • Page 57: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    K50A: every 5,000 km (3,107 mi) / after every race K100A: every 10,000 km (6,214 mi) J1A: annually J2A: every 2 years Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service. •...

  • Page 58: Maintenance Work On Chassis And Engine

    MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up front of motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the rear of the motorcycle. ( p.

  • Page 59: Jacking Up Rear Of Motorcycle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up rear of motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the work stand and screw it into the link forks. Work stand adapter (61029055110) Work stand rear (61029055100) –...

  • Page 60: Fork/Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .

  • Page 61: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce suspension damping.

  • Page 62: Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

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

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. – Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click.  Info Do not loosen nut ...

  • Page 64: Adjusting The Rebound Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info The high-speed setting can be seen during the fast compression of the shock absorber. – Turn adjusting screw clockwise as far as it will go using an open end wrench.  Info Do not loosen nut ...

  • Page 65: Bleeding The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise 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 700148-01...

  • Page 66: Checking Chain Dirt

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain dirt 9.13 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 64) Cleaning the chain 9.14 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 67: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – After drying, apply chain spray. Onroad chain spray ( p. 167) Checking the chain tension 9.15 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 68: Adjusting The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Lean the motorcycle on the side stand. – 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 must be taut.
  • Page 69 MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the chain tension. ( p. 65) – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right...

  • Page 70: Checking Rear Sprocket / Engine Sprocket For Wear

    The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. 100132-10 –...

  • Page 71: Checking Chain Wear

    A new chain will wear faster on an old, worn rear sprocket or engine sprocket. 700152-01 For safety reasons, the chain has no chain joint. Always have the chain changed in an authorized KTM workshop, where they have the necessary special tools.

  • Page 72: Checking Brake Discs

    Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. – Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement ...

  • Page 73: Adjusting Basic Position Of Handbrake Lever

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

  • Page 74: Adding Front Brake Fluid

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

  • Page 75: Checking The Front Brake Linings

    100181-10 Clean up overflowed or spilt brake fluid immediately with water. Checking the front brake linings 9.23 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop.

  • Page 76: Checking Free Play Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.

  • Page 77: Checking Rear Brake Fluid Level

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

  • Page 78: Adding Rear Brake Fluid

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

  • Page 79: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 100176-10 Checking the rear brake linings 9.27 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop.

  • Page 80: Removing Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.

  • Page 81: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosed screw and screw   – Screw out screw about 6 turns, press your hand on the screw to push the wheel spin-  dle out of the fork stub. Remove screw ...

  • Page 82: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. Info This will cause the brake caliper to align with the brake disc. – Fully tighten screws ...

  • Page 83: Installing The Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove nut . Remove chain adjuster . Holding the rear wheel, withdraw the wheel   spindle  – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. 100144-10 –...
  • Page 84 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the footbrake until the pressure point is reached. – Check the rear hub rubber dampers. p.

  • Page 85: Checking The Rear Hub Rubber Dampers

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Taking rear from work stand. ( p. 57) Checking the rear hub rubber dampers 9.32 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers.

  • Page 86: Checking The Tire Condition

    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 characteristics 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.

  • Page 87: Checking Tire Air Pressure

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle has been run in.

  • Page 88: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove dust cap. – Check tire air pressure when tires are cold. Tire air pressure, Solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) Rear...

  • Page 89: Mounting The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.36 – Suspend the seat on the screw , press the rear downwards and at the same time push  it forwards. The two projections must be inserted into the frame. ...

  • Page 90: Positioning The Fuel Tank

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

  • Page 91: Removing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Carefully move the fuel tank forwards and lower it. – Mount and tighten screw with bearing sleeve and rubber bushing . Check fuel    tank for tight fitting. Guideline Screw, fuel tank bracket 15 Nm (11.1 lbf ft) –...
  • Page 92 MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect the negative (minus) cable of the battery.  – Detach rubber band  700162-10 – Fold up positive terminal cover  – Disconnect the positive (plus) cable of the battery.  – Detach rubber band ...

  • Page 93: Installing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull battery up and out of the battery rack. Take the battery out of the frame toward  the right. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged.
  • Page 94 MAINTENANCE WORK ON CHASSIS AND ENGINE – Position cover  – Connect plug-in connector  700164-11 – Secure the cover with rubber band  – Connect positive cable . Position positive terminal cover   700163-11 – Secure the cover with rubber band ...

  • Page 95: Recharging The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Recharging the battery 9.41 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 96 MAINTENANCE WORK ON CHASSIS AND ENGINE – Switch off all power consumers and switch off the engine. – Reinstall the fuel tank. ( p. 87) – Disconnect the minus (negative) cable of the battery to avoid damage to the motorcy- cle's electronics.

  • Page 97: Changing The Main Fuse

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the main fuse 9.42 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is located in the starter relay housing next to the battery. –...

  • Page 98: Changing The Fuses Of Power Consumers

     – Insert the new main fuse. Fuse (58011109130) ( p. 153) 700167-01 Info If the new fuse burns out, contact an authorized KTM workshop. – Replace protective cover  – Position the fuel tank. ( p. 88) –...
  • Page 99 MAINTENANCE WORK ON CHASSIS AND ENGINE – Open fuse box cover  700168-01 – Remove the defective fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10A - clock, ignition (EFI control unit) Fuse 3 - 10A - throttle valve control unit Fuse 4 - 10A - fuel pump Fuse 5 - 10A - radiator fan...

  • Page 100: Adjusting The Engine Characteristic

    153) Fuse (75011088015) ( p. 153) Info If the new fuse burns out, contact an authorized KTM workshop. Put a new spare fuse in the fuse box for future use if needed. – Checking the function of power consumers.
  • Page 101 MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull the Map‑Select switch with holder downward off of the retaining bracket.  700196-10 – Position the Map‑Select switch on the outside of the frame. – Pull the Map‑Select switch out of the holder. 700197-01 –...

  • Page 102: Removing Headlight Mask With Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Set the Map‑Select switch to Advanced. – Set the adjusting wheel to position 2. Advanced – homologated performance with extremely direct responsiveness Set the Map‑Select switch to Standard. – Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9. Standard –...
  • Page 103 MAINTENANCE WORK ON CHASSIS AND ENGINE – Swing the headlight mask forward. 700170-10 – Disconnect plug-in connector. 700171-01 – Remove the screw fitting on both sides.  – Place the headlight mask to one side. 700172-10...

  • Page 104: Installing The Headlight Mask With The Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the headlight mask with the headlight 9.46 – Position the headlight mask. Mount and tighten screws on both sides.  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) 700172-11 – Connect the plug-in connector. 700171-01...

  • Page 105: Changing The Low Beam Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Fold the headlight mask up. 700170-11 – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check the lighting function. 700169-11 Changing the low beam bulb 9.47 Note Damage to reflector Keep the glass of the bulb free of grease.
  • Page 106 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws  700169-10 – Fold the headlight mask forward. 700170-10...
  • Page 107 MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn headlight lamp counterclockwise and remove it. Detach the connector.  – Position the new headlight bulb in the headlight housing. Connect the connector. Low beam/high beam (HB3/P20d) ( p. 153) Info Insert the headlight bulb so that the bayonet lugs latch into the slots. 600828-10 –...

  • Page 108: Change The High Beam Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check lighting function. 700169-12 Change the high beam bulb 9.48 Note Damage to reflector Keep the glass of the bulb free of grease. –...
  • Page 109 MAINTENANCE WORK ON CHASSIS AND ENGINE – Fold the headlight mask forward. 700170-10 – Turn headlight lamp counterclockwise and remove it. Detach the connector.  – Position the new headlight bulb in the headlight housing. Connect the connector. Low beam/high beam (HB3/P20d) ( p.

  • Page 110: Changing The Parking Light Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Fold the headlight mask up. 700170-11 – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check lighting function. 700169-12 Changing the parking light bulb 9.49 Note Damage to reflector Keep the glass of the bulb free of grease.

  • Page 111: Changing The Flasher Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the headlight mask with the headlight. ( p. 100) – Set down the headlight mask in front of you as shown in the illustration and carefully tilt the high beam headlight in the direction of the low beam headlight. –...

  • Page 112: Checking The Low Beam Headlight Adjustment

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the screw from the rear of the flasher housing. – Tilt headlamp diffuser forward carefully and take it off.  – Press the flasher bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket.

  • Page 113: Checking The High Beam Headlight Adjustment

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the low beam headlight adjustment. The boundary between light and dark must be exactly on the lower mark for a motor- cycle with driver. » If the boundary between light and dark does not meet specifications: –...

  • Page 114: Adjusting The Light Range Of The Low Beam Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the light range of the low beam headlight 9.53 – Adjust the light range of the low beam headlight. ( p. 112) – Remove screws  – Fold the headlight mask forward. 700169-10 –...

  • Page 115: Adjusting The Light Range Of The High Beam Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Fold the headlight mask up. – Position the headlight mask. Mount and tighten screws  Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) – Check the low beam headlight adjustment. ( p. 110) »...
  • Page 116 MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust the beam distance of the headlight by turning screw  Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (the mark is created in: Checking headlight adjustment). Info Turn clockwise to increase the beam width;...

  • Page 117: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system 9.55 The water pump in the engine forces the coolant to flow.  The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap .
  • Page 118 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact 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 119 MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. –...

  • Page 120: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the coolant level 9.57 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other components of the cooling system when the engine is hot. Allow the engine and radiator to cool down.

  • Page 121: Draining The Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap and check the coolant level in the radiator.  The radiator must be completely filled. » If the coolant level does not meet specifications: – Rectify the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p.

  • Page 122: Filling/Bleeding The Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact 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 123 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove radiator cap  700182-10 – Remove bleeder screw  – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten the bleeder screw immediately.

  • Page 124: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space without an effective exhaust extraction system.

  • Page 125: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  100116-10 Checking/rectifying the fluid level of the hydraulic clutch 9.61 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid.

  • Page 126: Checking Play In Gas Bowden Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking play in gas Bowden cable 9.62 – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the gas Bowden cable. Play in gas Bowden cable 3…...

  • Page 127: Adjusting The Play In The Gas Bowden Cable

    Adjusting the play in the gas Bowden cable 9.63 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the neutral position. – Loosen counter nut  – Set the play in the gas Bowden cable by turning the adjusting screw ...

  • Page 128: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the engine oil and filter, cleaning the oil screens 9.65 – Drain the engine oil. p. 126) – Remove the oil filter. p. 127) – Clean the oil screens. p. 129) – Install the oil filter. p.

  • Page 129: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring.  – Completely drain the engine oil. 700186-01 – Thoroughly clean the oil drain plug with a magnet. –...
  • Page 130 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations. – Place a suitable container under the engine. – Remove screws .

  • Page 131: Installing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the oil filter 9.68 – Insert oil filters   – Oil the O-rings of the oil filter cover. Mount oil filter covers   – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 700190-01 Cleaning the oil screens...
  • Page 132 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations. – Place a suitable container under the engine. – Remove plug with oil screen and the O-rings.

  • Page 133: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen with the O-rings.  – Mount and tighten plug with the O-ring.  Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 700193-01 – Position oil screen with the O-rings. ...

  • Page 134: Adding Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove filler plug with O-ring from the clutch cover and add engine oil.  Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 163) Alternative engine Engine oil (SAE 10W/50) p.
  • Page 135 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the oil filler plug with O-ring from the clutch cover and fill up with engine  oil. Engine oil (SAE 10W/60) (00062010035) ( p. 163) Engine oil (SAE 10W/50) ( p. 163) Info For optimal performance of the engine oil, do not mix different types of engine oil.

  • Page 136: Troubleshooting

    Clean socket connector and treat it with contact dized spray. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine has too little power. Air filter very dirty Have the air filter changed.
  • Page 137 Possible cause Action – Engine has too little power. Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
  • Page 138 TROUBLESHOOTING Faults Possible cause Action – Time is not (correctly) displayed Fuse 2 blown Change the fuses of power consumers. ( p. 96) – Set the clock. ( p. 28) – Battery discharged Ignition not switched off when vehicle Recharge the battery. p.

  • Page 139: Flashing Code

    FLASHING CODE Flashing code FI of warning lamp 02 FI warning lamp (MIL) flashes briefly 2x (MIL) Possible cause Malfunction in ignition pulse generator circuit Flashing code FI of warning lamp 06 FI warning lamp (MIL) flashes briefly 6x (MIL) Possible cause Input signal of throttle valve sensor circuit A too low Input signal of throttle valve sensor circuit A too high...
  • Page 140 FLASHING CODE Flashing code FI of warning lamp 13 FI warning lamp (MIL) flashes 1x long, 3x short (MIL) Possible cause Input signal from intake air temperature sensor too low Input signal from intake air temperature sensor too high Flashing code FI of warning lamp 14 FI warning lamp (MIL) flashes 1x long, 4x short (MIL) Possible cause...
  • Page 141 FLASHING CODE Flashing code FI of warning lamp 26 FI warning lamp (MIL) flashes 2x long, 6x short (MIL) Possible cause Malfunction in circuit of Hall sensor throttle valve control Flashing code FI of warning lamp 27 FI warning lamp (MIL) flashes 2x long, 7x short (MIL) Possible cause Malfunction in the EPT control unit power supply circuit...
  • Page 142 FLASHING CODE Flashing code FI of warning lamp 54 FI warning lamp (MIL) flashes 5x long, 4x short (MIL) Possible cause Interruption/short-circuit to ground in secondary air valve circuit Flashing code FI of warning lamp 58 FI warning lamp (MIL) flashes 5x long, 8x short (MIL) Possible cause Malfunction of release of throttle stepper motor in EPT mode...
  • Page 143 FLASHING CODE Flashing code FI of warning lamp 92 FI warning lamp (MIL) flashes 9x long, 2x short (MIL) Possible cause Malfunction in voltage supply circuit of EPT control unit (internal)

  • Page 144: Cleaning

    CLEANING Cleaning motorcycle 12.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.
  • Page 145 CLEANING Warning Danger of accidents Reduced braking due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

  • Page 146: Protection For Winter Operation

    PROTECTION FOR WINTER OPERATION Conservation for winter operation 13.1 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 you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt. –...

  • Page 147: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the rear of the motorcycle. ( p. 57) –...

  • Page 148: Putting Into Operation After Storage

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

  • Page 149: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11.8:1 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 150: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter, automatic decompressor...

  • Page 151: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite...
  • Page 152 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, locking lever 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, rocker arm shaft 12 Nm (8.9 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite...
  • Page 153 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –...

  • Page 154: Technical Data - Chassis

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

  • Page 155: Lighting Equipment

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

  • Page 156: Capacity - Fuel

    160/60 R 17 M/C 69H TL Dunlop Sportmax GPR Alpha 10 Dunlop Sportmax GPR Alpha 10 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 17.2 Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 157: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7E.09 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks...

  • Page 158: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7E.09 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2.5 turns Standard 2.0 turns Sport 1.5 turns Full payload 1.5 turns Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport...
  • Page 159 TECHNICAL DATA - SHOCK ABSORBER Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Riding sag 60… 65 mm (2.36… 2.56 in) Fitted length 376 mm (14.8 in) Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p.

  • Page 160: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, combination instrument 1 Nm (0.7 lbf ft) – Screw, combination instrument holder 1 Nm (0.7 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) ® Screw, side stand switch 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 161 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, fuel tap Tightening sequence: tighten in parallel 6 Nm (4.4 lbf ft) – Screw, headlight mask 5 Nm (3.7 lbf ft) ® Screw, horn 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, license plate holder 8 Nm (5.9 lbf ft) –...
  • Page 162 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, manifold on main silencer 25 Nm (18.4 lbf ft) Copper paste ® Screw, rear brake disc 30 Nm (22.1 lbf ft) Loctite 243™ ® Screw, rear footrest bracket 25 Nm (18.4 lbf ft) Loctite 243™...
  • Page 163 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) – Adjusting ring of swingarm bearing M24x1.5 25 Nm (18.4 lbf ft) – Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) – Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)

  • Page 164: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 165 168) (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 166 – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
  • Page 167 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 168: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Protect & Shine 645...
  • Page 169 AUXILIARY SUBSTANCES Long-life grease Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Fett 2000 Motorcycle cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Onroad chain spray Specification – ® KTM recommends Motorex products.

  • Page 170: 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 171: Index

    INDEX checking for wear ......69 INDEX cleaning ........64 Accessories .
  • Page 172 INDEX Coolant draining ........119 Filler cap Coolant level closing .
  • Page 173 INDEX Fuse Loading the vehicle ....... 40 power consumers, changing ..... . 96 Low beam bulb changing .
  • Page 174 INDEX Parking light bulb Service schedule ......53-55 changing ........108 Shift lever .
  • Page 175 INDEX Tire condition checking ........84 Tool set .
  • Page 176 *3211370en* 3211370en 10/2008 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

2009 690 duke aus/uk2009 690 duke jp2009 690 duke eu

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