KTM 690 Duke EU 2014 Manual

SETUP INSTRUCTIONS 2014
690 Duke EU
690 Duke AU/GB
690 Duke US
690 Duke MY
690 Duke R EU
690 Duke R AU/GB
690 Duke R MY
Art. no. 3213153en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est 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 AG specifically reserves the right to modify or delete technical specifica-
tions, 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 illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2014 KTM-Sportmotorcycle AG, 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 assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
201895-10
–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 fin-
ished.
–Check the vehicle for transport damage.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
201896-10
–Remove the controls from the transport holder. Remove the screws and handlebar
clamps. Remove the transport holder.
201897-10
–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)
100322-10
–Position the handlebar.
Marking 1on the scale on the handlebar is situated in the middle of the han-
dlebar clamp.
–Position the handlebar clamps. Tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
–Mount and tighten the right handlebar weight.
–Check the throttle grip for smooth operation.
201898-10
–Position the controls on the left half of the handlebar.
Info
Position holding lug in the drill hole of the handlebar.
–Position all controls in their exact positions on the handlebar. Tighten all screws.
201899-10
–Mount and tighten the rear mirror adapter and rear mirror on both sides.

2 SETUP 4
201900-10
–Mount the footrests with the springs and bolts. Secure the pins with the lock rings.
Pliers for footrest spring (58429083000)
201901-10
–Mount the reflector.
–Remove the protective plastic.
–Carefully loosen and remove the tensioning belt over the swingarm.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the pallet.
201902-10
–Mount clip-in nut on both sides. Hook the holdings lugs of the covers into the
tabs. Mount and tighten screw.
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.
–Keep sparks and open flames away from the battery. Only charge in
well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery
acid gets in the eyes, rinse with water for at least 15 minutes and con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 5)
–Install the battery. ( p. 6)
–Refuel. ( p. 7)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( p. 7)

3 WORK 5
3.1 Removing the passenger seat
B00928-10
–Insert the ignition key in seat lock and turn it clockwise.
–Raise the rear of the passenger seat, push it towards the rear, and remove it
upward.
–Remove the ignition key from the seat lock.
3.2 Mounting the passenger seat
B00940-10
–Hook catches of the passenger seat onto the storage compartment, lower the
rear, and simultaneously push forward.
–Press down the passenger seat until it clicks into place.
Warning
Danger of accidents The passenger seat can come loose from the anchoring
if it is not mounted correctly.
–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 goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
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 sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the passenger seat. ( p. 5)

3 WORK 6
–Disconnect the negative cable of the battery to avoid damage to the motorcycle's
electronics.
B00964-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the rest potential and start potential of
the battery, and to test the alternator. With this device, you cannot overcharge the
battery.
Info
Never remove lid .
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage, and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Finishing work
–Mount the passenger seat. ( p. 5)
–Set the clock. ( p. 7)
3.4 Installing the battery
B00963-11
Main work
–Position the battery in the battery holder.
Info
The terminals of the battery must face in the direction of travel.
–Attach rubber band .
–Reconnect the positive cable of the battery.
Guideline
Screw, battery terminal M6 2 Nm (1.5 lbf ft)
–Position positive terminal cover .
B00962-11
–Connect the negative cable of the battery.
Guideline
Screw, battery terminal M6 2 Nm (1.5 lbf ft)
Finishing work
–Mount the passenger seat. ( p. 5)
–Set the clock. ( p. 7)

3 WORK 7
3.5 Setting the clock
Condition
The motorcycle is stationary.
401444-01
–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.
–Press the MODE button to set the hour.
–Press the SET button to set the minute.
–Keep the MODE button and the SET button pressed simultaneously.
The time is set.
3.6 Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is stationary.
401444-01
–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.
3.7 Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel 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.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Note
Material damage Premature clogging of the fuel filter.
–In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.
–Only refuel with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.

3 WORK 8
B00935-10
–Switch off the engine.
–Open the filler cap. ( p. 8)
–Fill the fuel tank with fuel up to the lower edge of the filler neck.
Total fuel tank
capacity, approx.
13.8 l
(3.65 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 12)
–Close the filler cap. ( p. 8)
401429-10
–Press the SET button for two seconds.
The low fuel warning lamp switches off. TRIP F is set to 0 and the previous
display mode appears.
Info
If you do not press the SET button , the reset takes place automatically
after about three minutes.
3.8 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel 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.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
B00926-10
–Lift cover of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–To take pressure off of the ignition key, push down on the filler cap. Damaged
ignition keys must be replaced.
–Turn the ignition key 90° clockwise.
–Open the filler cap.
3.9 Closing the filler cap
B00927-01
–Fold down the filler cap.
–Turn the ignition key 90° clockwise.
–Press down the filler cap and turn back the ignition key until the lock locks.
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your
health.
–After closing the filler cap, ensure that it is locked properly. Change
clothing that has been contaminated with fuel. Immediately clean con-
taminated areas on the skin with soap and water.

3 WORK 9
–Remove the ignition key and close the cover.

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 10
Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) –
Screw, headlight EJOT 2 Nm (1.5 lbf ft) –
Screw, headlight mask EJOT 1 Nm (0.7 lbf ft) –
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite®243™
Remaining screws, chassis M5 5 Nm (3.7 lbf ft) –
Retaining clamp, brake line M5 3 Nm (2.2 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, foot brake lever stub (Duke,
690 Duke US, 690 Duke MY)
M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft) –
Screw, fuel pump M5 4 Nm (3 lbf ft) –
Screw, heat guard M5 5 Nm (3.7 lbf ft) Loctite®243™
Screw, light switch mount and emer-
gency OFF switch
M5 3.5 Nm (2.58 lbf ft) –
Screw, plastic clamp of brake line on
fork leg
M5 2 Nm (1.5 lbf ft) –
Screw, pressure regulator M5 4 Nm (3 lbf ft) –
Bolt, headlight mask M6 6.3 Nm (4.65 lbf ft) Loctite®243™
Chain guard M6 4 Nm (3 lbf ft) Loctite®243™
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, 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 fluid reservoir of rear
brake
M6 5 Nm (3.7 lbf ft) –
Screw, chain sliding guard M6 10 Nm (7.4 lbf ft) Loctite®243™
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, foot brake lever stub (Duke R) M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, fuel spoiler M6 3 Nm (2.2 lbf ft) –
Screw, lower radiator bracket M6 5 Nm (3.7 lbf ft) –
Screw, magnetic holder on side stand M6 10 Nm (7.4 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) –
Shift rods, nut M6 6 Nm (4.4 lbf ft) –
Shift rods, nut M6LH 6 Nm (4.4 lbf ft) –
Main silencer holder (Duke R) M8x40 25 Nm (18.4 lbf ft) –
Main silencer holder (Duke R) M8x60 25 Nm (18.4 lbf ft) –
Nut, manifold on cylinder head M8 25 Nm (18.4 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, exhaust system M8 25 Nm (18.4 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, footrest bracket, rear M8x20 Countersunk screw
25 Nm (18.4 lbf ft)
Loctite®243™

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 11
Screw, footrest bracket, rear M8x45 Countersunk screw
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®243™
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 clamp (Duke R) M8 15 Nm (11.1 lbf ft) –
Screw, main silencer fixation M8 25 Nm (18.4 lbf ft) –
Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite®243™
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) –
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 22 Nm (16.2 lbf ft) –
Banjo bolt, pressure modulator M10x1 20 Nm (14.8 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) –

5 SUBSTANCES 12
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).

*3213153en*
3213153en
01/2014
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM