KTM 690 Duke 2018 Manual

SETUP INSTRUCTIONS 2018
690 Duke
Art. no. 3213788en

INTRODUCTION
*3213788en*
3213788en
08/2017
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete
technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice
and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular
model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2017 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
690 Duke EU (F9703R4)
690 Duke US (F9775R3, F9775R4)

1 MEANS OF REPRESENTATION
2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Unpacking and setting up the vehicle
E00601-01
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle while mounting the
handlebar, leave the film on the fuel tank until all of
the work on the motorcycle has been finished.
–Check the vehicle for transport damage.
–Unpack the separate enclosure and check its contents on the
basis of the enclosure list.
(690 Duke US)
–Ensure that the reflector is mounted on the license plate
holder.
E00602-01
–Remove the controls from the transport holder. Remove the
screws and handlebar clamps. Remove the transport holder.
K00451-01
–Remove the right-hand handlebar weight.
–Position the controls on the right half of the handlebar.
Tighten the screws.
Guideline
Screw, throttle grip M5 3.5 Nm
(2.58 lbf ft)
E00174-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the screws
evenly.

2 SETUP
4
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Info
The markings on the handlebar should be at the center
of the handlebar clamps.
Keep the gap widths equal when tightening.
–Mount and tighten the right handlebar weight.
–Check the throttle grip for smooth operation.
K00452-01
–Position the controls on the left half of the handlebar.
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
M01519-01
–Mount and tighten the rear mirror adapter and rear mirror on
both sides.
H00385-01
–Mount the footrests with the springs and pins. Secure the pins
with the lock rings.
Footrest spring plier (58429083000)
F01045-10
–Mount reflector 1with spring washers 2on holding
plate 3.
–Mount the retaining plate on the license plate holder.
–Mount the license plate holder.
–Remove the protective film.
–Carefully loosen and remove the tension belt over the
swingarm.
Info
An assistant prevents the motorcycle from falling over.

SETUP 2
5
–Carefully loosen and remove the tension belts around the lower
triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the pallet.
–Remove the radiator shield.
–Remove the passenger seat. ( p. 6)
–Remove the spare key and KEYCODECARD and keep in a safe
place for the handover.
–Secure the tool set with rubber holders under the passenger
seat.
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 safety
glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and
consult a doctor immediately if battery acid and
battery gases get into the eyes.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 6)
–Install the battery. ( p. 8)
–Refuel. ( p. 10)
–Check the headlight setting. ( p. 12)
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.
–Set the kilometers or miles. ( p. 10)

3 WORK
6
3.1 Removing the passenger seat
V00043-10
–Insert the ignition key in seat lock 1and turn it clockwise.
–Raise the rear of the passenger seat, push it towards the rear,
and remove it upward.
–Remove the ignition key from the seat lock.
3.2 Mounting the passenger seat
K00421-10
–Hook catches 1of the passenger seat onto the storage com-
partment, 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.
–After mounting the passenger seat, check that it is
locked correctly by pulling up.
–Finally, check that the passenger seat is correctly mounted.
3.3 Recharging 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 safety glasses.
–Avoid contact with battery acid and battery gases.
–Keep sparks or open flames away from the battery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and
battery gases get into the eyes.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

WORK 3
7
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-
fated, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Switch off the ignition by turning the ignition key to the posi-
tion .
–Remove the passenger seat. ( p. 6)
–Disconnect the negative cable of the battery. ( p. 8)
311910-10
Main work
–Connect the battery charger to the battery. Adjust the battery
charger.
EU battery charger XCharge-professional (00029095050)
Alternative 1
US battery charger XCharge-professional
(00029095051)
Alternative 2
UK battery charger XCharge-professional
(00029095052)
Alternative 3
CH battery charger XCharge-professional
(00029095053)
Info
Follow the instructions of the charger and the manual.
–Switch off the battery charger after charging and disconnect
from the battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Charge the battery regularly
when the motorcycle is not
in use
3 months
Finishing work
–Connect the negative cable of the battery. ( p. 9)
–Mount the passenger seat. ( p. 6)
–Set the time and date. ( p. 9)

3 WORK
8
3.4 Installing the battery
V00579-10
Main work
–Position the battery in the battery holder.
Battery (HTZ12A-BS)
The battery terminals face opposite the direction of travel.
–Reconnect rubber band 1.
–Connect both positive cables 2to the battery.
Guideline
Screw, battery termi-
nal
M6 2 Nm (1.5 lbf ft)
–Mount positive terminal cover 3.
V00580-11
–Connect negative cable 4to the battery.
Guideline
Screw, battery termi-
nal
M6 2 Nm (1.5 lbf ft)
Finishing work
–Mount the passenger seat. ( p. 6)
–Set the time and date. ( p. 9)
3.5 Disconnecting the negative cable of the battery
Preparatory work
–Switch off the ignition by turning the ignition key to the posi-
tion .
–Remove the passenger seat. ( p. 6)
V00580-10
Main work
–Disconnect negative cable 1of the battery.

WORK 3
9
3.6 Connecting the negative cable of the battery
V00580-10
Main work
–Connect negative cable 1. Tighten the screw.
Guideline
Screw, battery termi-
nal
M6 2 Nm (1.5 lbf ft)
Finishing work
–Mount the passenger seat. ( p. 6)
–Set the time and date. ( p. 9)
3.7 Set the time and date
Condition
The motorcycle is stationary.
K00393-01
–Press the UP or DOWN button until the "Settings" menu appears
on the display. Pressing the SET button opens the menu.
–Press the UP or DOWN button until the "Clock-date set" menu is
marked on the display. Pressing the SET button again sets the
unit of measure.
–Press the SET button.
The hour next to "Clock" flashes.
–Press the UP or DOWN button until the current hour is set.
–Press the SET button.
The minute next to "Clock" flashes.
–Press the UP or DOWN button until the current minute is set.
–Press the SET button.
The day next to "Date" flashes.
–Press the UP or DOWN button until the current day is set.
–Press the SET button.
The month next to "Date" flashes.
–Press the UP or DOWN button until the current month is set.
–Press the SET button.
The year next to "Date" flashes.
–Press the UP or DOWN button until the current year is set.
–Press the BACK button.
Time and date are saved.

3 WORK
10
3.8 Setting the kilometers or miles
Info
If the unit is changed, the value is retained and converted accordingly.
Make the setting according to the country.
Condition
The motorcycle is stationary.
H02604-01
–Press the UP or DOWN button until the "Settings" menu appears
on the display. Pressing the SET button opens the menu.
–Press the UP or DOWN button until "Distance" is marked on the
display. Pressing the SET button again sets the unit of mea-
sure.
–Select kilometers "km" or miles "mi" for the distance.
3.9 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.

WORK 3
11
B00935-10
–Switch off the engine.
–Open the filler cap. ( p. 11)
–Fill the fuel tank with fuel up to the lower edge Aof the filler
neck.
Total fuel tank
capacity, approx.
14 l
(3.7 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 17)
–Close the filler cap. ( p. 12)
3.10 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
V00556-10
–Lift cover 1of the filler cap and insert the ignition key in the
lock.
Note
Danger of damage The ignition key may break if overloaded.
Damaged ignition keys must be replaced.
–Push down on the filler cap to take pressure off the igni-
tion key.
–Turn the ignition key 90° clockwise.
–Open the filler cap.

3 WORK
12
3.11 Closing the filler cap
V00557-01
–Fold down the filler cap.
–Turn the ignition key 90° clockwise.
–Push down the filler cap and turn the ignition key counter-
clockwise until the lock closes.
Warning
Fire hazard Fuel is highly flammable, toxic and a
health hazard.
–Check the filler cap is locked correctly after clos-
ing.
–Change your clothing in case of fuel spills on them.
–Rinse the affected area immediately with plenty of
water in the event of contact with the skin.
–Remove the ignition key and close the cover.
3.12 Checking the headlight setting
400726-10
–Position the vehicle upright on a horizontal surface in front of
a light wall and make a mark at the height of the center of the
low beam headlight.
–Make another mark at a distance Bunder the first mark.
Guideline
Distance B5 cm (2 in)
–Position the vehicle perpendicular to the wall at a distance A
from the wall and switch on the low beam.
Guideline
Distance A5 m (16 ft)
–The rider, with luggage and passenger if applicable, now
mounts the motorcycle.
–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 light-dark border does not meet specifications:
–Adjust the headlight range. ( p. 13)

WORK 3
13
3.13 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 12)
V00067-10
Main work
–Adjust the beam distance of the headlight by turning
screw 1.
Guideline
For a motorcycle with rider, and with luggage and a passen-
ger if applicable, the light/dark boundary must be exactly on
the lower mark (applied in: Checking the headlight setting).
Info
Turn counterclockwise to increase the headlight range;
turn clockwise to reduce the headlight range.
If you have a payload, you may have to correct the
headlight range.

4 TECHNICAL DATA
14
4.1 Chassis tightening torques
Screw, headlight EJOT 2 Nm (1.5 lbf ft)
Screw, side stand switch M4 2 Nm (1.5 lbf ft)
Loctite®243™
Remaining nuts, chassis M5 4 Nm (3 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Retaining clamp, brake line M5 3 Nm (2.2 lbf ft)
SAS valve screw on frame M5 4 Nm (3 lbf ft)
Screw, air filter box M5 3 Nm (2.2 lbf ft)
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft)
Screw, combination instrument M5 4 Nm (3 lbf ft)
Screw, combination switch, left M5 1.5 Nm (1.11 lbf ft)
Screw, combination switch, right M5 3.5 Nm (2.58 lbf ft)
Screw, foot brake lever stub M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft)
Screw, fuel tank lid fitting M5 3 Nm (2.2 lbf ft)
Screw, headlight mask M5 4 Nm (3 lbf ft)
Screw, heat guard M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, plastic clamp of brake line
on fork leg
M5 2 Nm (1.5 lbf ft)
Double-sided grub screw M6 6 Nm (4.4 lbf ft)
Loctite®243™
Nut, push rod, foot brake lever M6 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, angle sensor M6 5 Nm (3.7 lbf ft)
Screw, ball joint of push rod on
foot brake cylinder
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, battery terminal M6 2 Nm (1.5 lbf ft)
Screw, brake assembly M6 5 Nm (3.7 lbf ft)
Screw, brake fluid reservoir of rear
brake
M6 5 Nm (3.7 lbf ft)
Screw, chain guard M6 4 Nm (3 lbf ft)
Loctite®243™
Screw, chain sliding guard M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch assembly M6 5 Nm (3.7 lbf ft)
Screw, control unit holder M6 3 Nm (2.2 lbf ft)
Screw, exhaust pipe clamp M6 8 Nm (5.9 lbf ft)
Copper paste
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, fuel pump M6 6 Nm (4.4 lbf ft)
Screw, fuel spoiler M6 3 Nm (2.2 lbf ft)
Screw, lower radiator bracket M6 5 Nm (3.7 lbf ft)

TECHNICAL DATA 4
15
Screw, magnetic holder on side
stand
M6 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, seat lock M6 10 Nm (7.4 lbf ft)
Loctite®222™
Screw, tail light cover M6 8 Nm (5.9 lbf ft)
Screw, voltage regulator M6 8 Nm (5.9 lbf ft)
Screw, wheel speed sensor M6 6 Nm (4.4 lbf ft)
Nut, manifold on cylinder head M8 20 Nm (14.8 lbf ft)
Copper paste
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, footrest bracket, rear M8x30 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, footrest bracket, rear M8x50 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, front brake disc M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
Screw, handrail M8x30 Countersunk screw
18 Nm (13.3 lbf ft)
Loctite®243™
Screw, handrail, cover M8x20 18 Nm (13.3 lbf ft)
Loctite®243™
Screw, ignition lock (tamper-proof
screw)
M8
Loctite®243™
Screw, license plate holder M8 18 Nm (13.3 lbf ft)
Loctite®243™
Screw, linkage bracket, front
engine fixing arm
M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, main silencer fastening M8 25 Nm (18.4 lbf ft)
Screw, rear brake disc M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, side stand bracket M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, spring holder on side stand
bracket
M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft)
Engine carrying screw M10 45 Nm (33.2 lbf ft)
Loctite®243™
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)
Remaining screws, chassis M10 45 Nm (33.2 lbf ft)
Screw, foot brake lever M10 25 Nm (18.4 lbf ft)
Screw, handlebar support M10 20 Nm (14.8 lbf ft)

4 TECHNICAL DATA
16
Screw, side stand M10 35 Nm (25.8 lbf ft)
Loctite®243™
Screw, subframe M10 45 Nm (33.2 lbf ft)
Loctite®243™
Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft)
Screw, bottom shock absorber M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, top shock absorber M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft)
Nut, frame to linkage lever M14x1.5 100 Nm (73.8 lbf ft)
Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft)
Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft)
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)
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)
Nut, steering head M28x1 12 Nm (8.9 lbf ft)

SUBSTANCES 5
17
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
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).

*3213788en*
3213788en
08/2017
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM