Table of Contents
Advertisement
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for KTM 2009 690 Rally Factory Replica
Summary of Contents for KTM 2009 690 Rally Factory Replica
- Page 1 OWNER'S MANUAL 2009 690 Rally Factory Replica ART. NO. 3211361en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.
-
Page 4: Table Of Contents
LOCATION OF SERIAL NUMBERS ........7 Important maintenance work to be carried out by an Chassis number............... 7 authorized KTM workshop. (as additional order)....28 Type label............... 7 Important checks and maintenance work to be carried Key number ..............7 out by the rider. - Page 5 CONTENTS SUBSTANCES..............96 Mounting the front wheel ........... 51 AUXILIARY SUBSTANCES..........98 Removing rear wheel ..........52 STANDARDS..............99 Mounting the rear wheel ..........53 INDEX ................100 Checking the tire condition..........53 Checking tire air pressure ..........54 Checking spoke tension..........54 Removing the trim ............
-
Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 7: Important Notes
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be granted for damage resulting from manipulations and/or alterations to the vehicle. - Page 8 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 poten- tial 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 9: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number Chassis number is embossed in the steering head at the right. 600001-10 Type label Type label is fixed to the right of the steering head. 600001-11 Key number The key number is stamped on the key strap. ... -
Page 10: Shock Absorber Part Number
LOCATION OF SERIAL NUMBERS Shock absorber part number Shock absorber part number is attached at the shock absorber unit, to the rear of the direction of travel. 600026-10... -
Page 11: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 600006-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. ... -
Page 12: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. -
Page 13: Tripmaster Switch
CONTROLS WS (wheel size) After the display function test, the wheel size WS is displayed briefly. Info 2205 mm corresponds to the size of the 21" front wheel with a series produc- tion tire. The display then changes to the last selected mode. 400314-01 Tripmaster switch 4.11... -
Page 14: Adjusting The Speedometer Functions
CONTROLS – Press the button for 3 - 5 seconds. The settings are saved and the Setup menu closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed. -
Page 15: Speed Display Mode (Speed)
CONTROLS SPEED display mode (speed) 4.16 – Press the button briefly and repeatedly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Making the setting according to the country. -
Page 16: Display Mode Speed/Odo (Odometer)
CONTROLS Press the button The stop watch and the lap time are reset. for 3 - 5 seconds. Press the button Next display mode briefly. Display mode SPEED/ODO (odometer) 4.20 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. -
Page 17: Disply Mode Speed/A1 (Average Speed 1)
CONTROLS Disply mode SPEED/A1 (average speed 1) 4.23 – Press the button briefly and repeatedly until A1 appears at the top right of the display. A1 (average speed 1) shows the average speed calculated using TR1 (trip master 1) and S1 (stop watch 1). -
Page 18: Fuses
CONTROLS Table of functions Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. Display mode SPEED/H No function No function The display changes to Next display mode (service hours) the Setup menu of the speedometer functions. -
Page 19: Fuel Tank
CONTROLS Fuse - Electric starter system Fuse - Radiator fan Fuse - lighting Sentinel (optional) Fuse - Roadbook Fuse - Not assigned Fuse - Lighting - GPS (optional) Fuse Fuse - Iritrac (optional) ... -
Page 20: Choke
CONTROLS F FRONT – If tap handle • of the fuel tap points toward the rear, fuel is taken from the two front fuel tanks. Only the front fuel tanks empty out completely. 600017-10 R REAR – If tap handle •... -
Page 21: Foot Brake Pedal
CONTROLS Foot brake pedal 4.32 Foot brake pedal is located in front of the right footrest. The rear brake is engaged with the foot brake pedal. 600023-10 Side stand 4.33 Note Danger of damage The parked vehicle can roll away or fall over. –... -
Page 22: Unlocking The Steering
CONTROLS – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible. Info Never leave the key in the steering lock. Unlocking the steering 4.36 –... -
Page 23: General Tips And Hints On Putting Into Operation
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 24: Running In The Engine
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 400 kg (882 lb.) Maximum permissible front axle load 190 kg (419 lb.) Maximum permissible rear axle load 250 kg (551 lb.) –... -
Page 25: Riding Instructions
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. -
Page 26: Starting Up
Info First gear is used for starting off or for steep inclines. If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta- neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. -
Page 27: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components get very hot when the machine is driven. –... - Page 28 RIDING INSTRUCTIONS – Fill the fuel tank with fuel no higher than mark Fuel tank capacity Fuel tank half, 9.0 l Super unleaded (ROZ 95 / RON 95 / front left, (2.38 US gal) PON 91) ( p. 97) approx.
-
Page 29: Service Schedule
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. K05N K15A K45A Engine • • • Change the engine oil and filter, clean the oil screens. p. 67) Check and adjust valve clearance. • •... -
Page 30: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)
K05N: after 500 km (310.7 mi) K15A: every 1,500 km (932 mi) K45A: every 4,500 km (2,796 mi) T1A: daily Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service. •... -
Page 31: Maintenance Work On Chassis And Engine
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set- tings of the suspension components must match your body weight. – As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Guideline Standard rider weight 75…... -
Page 32: Adjusting The Rebound Damping Of The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw of the low-speed damping and the high-speed damp- clockwise to the last perceptible click. – Turn back counterclockwise the number of clicks or turns corresponding to the shock absorber type. -
Page 33: Checking The Static Sag Of The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 30) – Ask someone to help you by holding the motorcycle upright. – Measure the distance between the rear axle and the fixed point again. 0 0 A –... -
Page 34: Checking The Riding Sag Of The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen screw 0 0 1 0 0 2 – Turn adjusting ring until the spring is no longer under tension. Combination wrench (50329080000) Hook wrench (T106S) – Measure the overall spring length when not under tension. –... -
Page 35: Removing The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust the rebound damping of the shock absorber. ( p. 30) Removing the shock absorber 8.13 – Jack up the motorcycle. ( p. 29) – Fold up the fuel tank at the rear. ( p. -
Page 36: Checking Basic Setting Of Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten screw Guideline Screw, bottom shock 45 Nm Loctite ® 243™ absorber (33.2 lbf ft) 600095-10 – Position the splash protector . Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –... -
Page 37: Adjusting The Rebound Damping Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the rebound damping of the fork 8.17 Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection covers – Turn adjusting screws clockwise until they stop. Info Adjusting screws are located at the bottom end of the fork legs. -
Page 38: Dismounting The Front Fender
Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. -
Page 39: Adjusting Play Of Steering Head Bearing
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting play of steering head bearing 8.23 – Remove screws . Remove the holding plate with handlebar clamps. – Remove screws . Remove the steering damper – Remove the trim. ( p. -
Page 40: Fork Offset
MAINTENANCE WORK ON CHASSIS AND ENGINE Fork offset 8.24 The fork offset has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing. The fork offset can optionally be adjusted. -
Page 41: Adjusting The Handlebar Position
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar position 8.26 – Remove the four screws . Remove the holding plate with handlebar clamps with intermediate rubber pieces and elastomers 0 0 1 – Remove the handlebar and lay it to one side. 0 0 2 Info 0 0 3... -
Page 42: Adjusting The Bowden Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the Bowden cable 8.27 – Remove the front fuel tank. ( p. 56) – Check the gas Bowden cable route. – Move the handlebar to the straight-ahead position. – To adjust, loosen lock nut , turn adjusting screw accordingly and retighten the ... -
Page 43: Checking The Rear Sprocket/Engine Sprocket For Wear
MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the chain at the end of the chain sliding piece up and determine the chain tension between the swingarm and the top edge of the chain. Info The upper chain section must be taut. -
Page 44: Adjusting Basic Setting Of Clutch Lever
Warning 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 at several places on the disc to see if it conforms to measurement ... -
Page 45: Checking Free Play Of Hand Brake Lever
Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 46: 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. Warning Environmental hazard Problem materials cause environmental damage. –... -
Page 47: Removing Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 48: Changing The Front Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –... -
Page 49: Checking Free Play Of Foot Brake Lever
Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –... -
Page 50: 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. Warning Environmental hazard Problem materials cause environmental damage. –... -
Page 51: Removing Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 52: Changing The Rear Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –... -
Page 53: Removing Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing front wheel 8.52 – Jack up the motorcycle. ( p. 29) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. -
Page 54: Removing Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the motorcycle from the work stand. ( p. 29) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Tighten screws ... -
Page 55: Mounting The Rear Wheel
8.56 Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. -
Page 56: Checking Tire Air Pressure
Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. -
Page 57: Mounting The Trim
MAINTENANCE WORK ON CHASSIS AND ENGINE – Open the quick release brackets – Remove the trim toward the front. 600081-10 Mounting the trim 8.60 – Insert the trim at the guides Info When positioning the trim, exercise caution with the quick releases ... -
Page 58: Mounting The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 8.62 – Put down the seat and fit it into collar sleeves of the fuel tank at the rear. Push the seat forward at the same time. – Push the seat down at the front, lift the quick release bracket and turn it in the ... -
Page 59: Folding Up The Fuel Tank At The Rear
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) – Connect the hoses of the fuel tank breather without kinking. – Mount the seat. ( p. 56) –... -
Page 60: Lowering The Fuel Tank At The Rear
MAINTENANCE WORK ON CHASSIS AND ENGINE – Fold the rear tank upward in the direction of the arrow and use a belt to secure it to the handlebar. 600091-11 Lowering the fuel tank at the rear 8.66 Danger Fire hazard Fuel can easily catch fire. –... -
Page 61: Removing The Motor Guard
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw Guideline Screw, rear tank fixing 20 Nm Loctite ® 243™ bracket (14.8 lbf ft) – Clean and connect the quick releases of the fuel line with each other. ... -
Page 62: Checking The Headlamp Setting
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws Guideline Screw, motor guard 25 Nm (18.4 lbf ft) 600073-11 Checking the headlamp setting 8.69 – On a light-colored wall in front of which there is a horizontal surface, make a mark 0 0 A at the height of the center of the low beam headlamp. -
Page 63: Removing The Battery
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the battery 8.71 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 64: Removing The Main Fuse
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. -
Page 65: Checking The Coolant Level
A reserve fuse is located in the starter relay. Replace a burned-out fuse by an equivalent fuse only. If the new fuse burns out, contact an authorized KTM workshop. – Replace the protection cover. 600108-11 – Replace the protection cover. -
Page 66: Checking The Coolant Level And Antifreeze
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the coolant level and antifreeze 8.77 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 67: Installing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. –... -
Page 68: Carburetor - Adjusting The Idle Speed
MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - adjusting the idle speed 8.81 – Turn handle of the fuel tap to the R REAR position. (Figure 600016-10 p. 18) – Remove the front fuel tank. ( p. 56) – Screw in idle adjusting screw until it stops and then to the prescribed basic set- ... -
Page 69: Checking The Engine Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the engine oil level 8.82 Info The engine oil level must be checked when the engine is warm. – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. –... -
Page 70: Removing The Oil Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 8.85 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage. -
Page 71: Cleaning The Oil Screens
MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the oil screens 8.86 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage. -
Page 72: Installing The Oil Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the oil filter 8.87 – Insert the oil filter – Oil the O-ring of the oil filter cover and mount it with the oil filter cover 600089-10 – Mount and tighten screws ... -
Page 73: Adding Engine Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the engine oil level. ( p. 67) Adding engine oil 8.89 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove screw connection on the clutch cover and fill up with engine oil. ... -
Page 74: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – Battery discharged Battery is not charged by generator Check the charging voltage. – Check the charging current. – Check the generator. – Unwanted power consumer Check the closed current. – Engine turns but does not start Operating error Carry out work steps for the start procedure. - Page 75 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Lack of fuel Refuel. ( p. 25) carburetor. – Engine takes in bad air Check rubber sleeves and carburetor for tight- ness. – Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
-
Page 76: Cleaning
CLEANING Cleaning motorcycle 10.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage. -
Page 77: 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 motorcycle. ( p. 29) –... -
Page 78: Technical Data - Engine
TECHNICAL DATA - ENGINE Design 1-cyliner 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11,8:1 Idle speed 1,600… 1,700 rpm Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust... -
Page 79: 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 80 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite 243™ ® Oil pressure sensor in the oil filter M10x1 5 Nm (3.7 lbf ft) Loctite 243™ cover – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) –...
-
Page 81: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 690 Rally Factory Replica 14.1 Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4100C Needle position 5 th position from top Idle mixture adjusting screw Open 2 turns Main jet Jet needle OBDYU (OBEKR) Idling jet Idle air jet Cold start jet... -
Page 82: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Trellis frame of chromium-molybdenum steel tubes, powder- coated Suspension travel Front 300 mm (11.81 in) Rear 310 mm (12.2 in) Fork offset Mark 1 visible 20 mm (0.79 in) No mark 22 mm (0.87 in) Brake system Disc brakes, brake calipers on floating bearings Brake discs - diameter... -
Page 83: Tires
90/90 - 21 54S TT 130/80 - 18 66S TT Michelin T63 Michelin T63 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 15.3 Fuel tank capacity Fuel tank half, front left, 9.0 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. -
Page 84: Technical Data - Fork
TECHNICAL DATA - FORK Fork part number 14.18.7E.10 Fork WP Suspension 4860 MXMA CC Compression damping Standard 12 clicks Rebound damping Standard 20 clicks Spring length with preload spacer(s) 502 mm (19.76 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 75…... -
Page 85: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7E.17 Shock absorber WP Suspensione 5018 DACC Compression damping, high-speed Standard 20 turns Compression damping, low-speed Standard 15 clicks Rebound damping Standard 20 clicks Spring preload Standard 14 mm Spring rate Weight of rider: 65…... -
Page 86: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining screws, chassis 4 Nm (3 lbf ft) – Screw, brake line on bottom triple 2 Nm (1.5 lbf ft) clamp ® Screw, foot brake pedal surface 6 Nm (4.4 lbf ft) Loctite 243™... -
Page 88: Wiring Diagram
WIRING DIAGRAM 690 Rally Factory Replica 1 of 3 19.1 63,134 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 C_AD/12 -X200 C_BD/12 9 10 11 12 32,33 C_AU/2 C_BI/2 400349-10... - Page 89 WIRING DIAGRAM Components: Battery Generator Starter relay with main fuse High beam relay Low beam relay Starter motor Radiator fan Voltage regulator/rectifier Gear sensor switch Thermoswitch Ignition lock Electric starter button Cable colors: Green Green Green Green Green Green Yellow-red Green Yellow-red Yellow-red...
- Page 90 WIRING DIAGRAM Yellow-blue Black-yellow Brown Brown Brown Brown Black Black-red Black-red White-green Black-green Green-red Pink Orange White-red Yellow-blue Brown Yellow Black-orange Orange Green Green...
- Page 91 WIRING DIAGRAM...
-
Page 92: Rally Factory Replica 2 Of 3
WIRING DIAGRAM 690 Rally Factory Replica 2 of 3 19.2 400350-10... - Page 93 WIRING DIAGRAM Components: CDI controller Throttle position sensor Temperature switch for indicator lamp Pulse generator Ignition coil Cable colors: Orange Brown Brown Blue Yellow Black Gray black-blue Gray Black-brown Black-yellow Black-yellow...
-
Page 94: Rally Factory Replica 3 Of 3
WIRING DIAGRAM 690 Rally Factory Replica 3 of 3 19.3 -H10 -H11 -H12 C_DI/2 C_CJ/2 C_CJ/2 C_CW/2 C_CW/2 C_CX/2 2.1 2.2 2.1 2.2 2.1 2.2 C_CX/2 C_AK/2 C_CX/2 C_CZ/3 C_DB/4 C_AK/2 C_AK/2 -X404 -X402 -X401 C_CW/2 C_AH/2 C_CY/3 C_DA/4 C_AH/2 C_AH/2 C_AK/2 -X403... -
Page 95: Wiring Diagram
WIRING DIAGRAM Components: Roadbook Not assigned Not assigned GPS (optional) Iritrac (optional) Wheel speed sensor Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Additional rear light (optional) Parking light ICO Light (optional) Roadbook Light Low beam High beam Horn... - Page 96 WIRING DIAGRAM Pink Yellow-blue Yellow-blue Yellow-blue Yellow-blue Brown Brown Brown Brown Brown Brown Brown Yellow-blue Orange Violet Violet Violet Violet Black Black Black Black Black Black Black Black Green-white Brown White Black-brown White-yellow White White White Brown Brown Brown Brown Brown Green-gray Blue-gray...
- Page 97 WIRING DIAGRAM White White White Brown Brown Brown Brown Brown Brown Brown Brown Black-yellow Black-green Brown...
- Page 98 – 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 99 According to – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the ® corresponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
- Page 100 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 101 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 specifi- cation.
- Page 102 INDEX INDEX Accessories ........5 Dust boots cleaning .
- Page 103 INDEX removing ....... . . 33 static sag, checking ......31 Ignition switch .
- Page 104 *3211361en* 3211361en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...
Need help?
Do you have a question about the 2009 690 Rally Factory Replica and is the answer not in the manual?
Questions and answers