KTM 690 Duke EU 2016 Manual

SETUP INSTRUCTIONS 2016
690 Duke
690 Duke R
Art. no. 3213436en

INTRODUCTION 1
*3213436en*
3213436en
02/2016
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.
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 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 assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
690 Duke EU (F9703P3, F9703P4)
690 Duke US (F9775P3, F9775P4)
690 Duke CN (F9787P4)
690 Duke R EU (F9703P1)
690 Duke R AU (F9760P1)

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.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
K00450-01
–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 fin-
ished.
–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.
E00173-10
–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
–Position the handlebar.
Marking 0on 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.
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.

2 SETUP 4
201899-10
–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.
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 tension belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the palette.
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)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.
–Set the kilometers or miles. ( p. 7)

3 WORK 5
3.1 Removing the passenger seat
V00043-10
–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
K00421-10
–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 dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 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 sulfated, 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 position .
–Remove the passenger seat. ( p. 5)
–Disconnect the negative cable of the battery.

3 WORK 6
H01143-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger XCharge-professional EU (00029095050)
Battery charger XCharge-professional US (00029095051)
Battery charger XCharge-professional GB (00029095052)
Battery charger XCharge-professional CH (00029095053)
Info
Follow the charger's instructions exactly.
–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.
–Mount the passenger seat. ( p. 5)
–Set the time and date. ( p. 7)
3.4 Installing the battery
K00447-01
Main work
–Position the battery in the battery holder.
Battery (CBTX9-BS)
The battery terminals face opposite the direction of travel.
–Reconnect rubber band .
–Connect both positive cables to the battery.
Guideline
Screw, battery terminal M6 2 Nm (1.5 lbf ft)
–Mount positive terminal cover .
K00445-10
–Connect negative cable to the battery.
Guideline
Screw, battery terminal M6 2 Nm (1.5 lbf ft)
Finishing work
–Mount the passenger seat. ( p. 5)
–Set the time and date. ( p. 7)

3 WORK 7
3.5 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 dis-
play. 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.
3.6 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.
K00382-01
–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 measure.
–Select kilometers "km" or miles "mi" for the distance.
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.

3 WORK 8
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.
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.
14 l (3.7 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 12)
–Close the filler cap. ( p. 9)
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 has been 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.
M00657-10
–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 WORK 9
3.9 Closing the filler cap
M00658-01
–Fold down the filler cap.
–Turn the ignition key 90° clockwise.
–Push down the filler cap and turn the ignition key counterclockwise until the lock
closes.
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.
–Remove the ignition key and close the cover.

4 TECHNICAL DATA 10
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 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 3.5 Nm (2.58 lbf ft) –
Screw, combination switch, right M5 3.5 Nm (2.58 lbf ft) –
Screw, foot brake lever stub (Duke) M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft) –
Screw, headlight mask M5 4 Nm (3 lbf ft) –
Screw, heat guard (Duke) 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, foot brake lever stub (Duke R) 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) –
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, shift lever (Duke R) M6 14 Nm (10.3 lbf ft) Loctite®243™
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) –
Shift rods, nut (Duke R) M6 6 Nm (4.4 lbf ft) –
Shift rods, nut (Duke R) M6LH 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, foot brake lever (Duke R) M8 20 Nm (14.8 lbf ft) –

4 TECHNICAL DATA 11
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 clamp (Duke R) M8 15 Nm (11.1 lbf ft) –
Screw, main silencer fastening (Duke) 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 (Duke) 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 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) –

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).

*3213436en*
3213436en
02/2016
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM