KTM 690 DUKE EU Packaging 4 2008 Manual

SETUP INSTRUCTIONS 2008
Packaging4
690DUKEEU
690DUKEAUS/UK
690DUKEJP
690DUKEUSA
ART. NO. 3211338en

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 in particular 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 prudction 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 delivery.
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of 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

MEANS OF REPRESENTATION 2
1MEANS OF REPRESENTAT ION
Symbols used
The symbols used are explained in the following.
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).
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Name Indicates a proprietary name.
Protected name®Identifies a protected name.
Trademark™ Identifies a brand in merchandise traffic.

SET‑UP 3
2SET‑UP
2.1Unpacking and setting up the vehicle
700211-01
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle when mounting the handlebar, do not
remove the plastic on the fuel tank until after all of the work has been com-
pleted.
–Check the vehicle for transport damage.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
700212-01
–Remove the operating elements from the transport holder. Remove the screws and
handlebar clamps. Remove the transport holder.
700213-01
–Position the operating elements on the right half of the handlebar.
–Position the handlebar.
–Position the handlebar clamps. Fit and slightly tighten the four screws.
100322-10
–Position the handlebar exactly.
The mark1of the scale on the handlebar should be in the center of the han-
dlebar clamp.
–Tighten the four screws evenly.
Guideline
Screw, handlebar clamp M8 20Nm
(14.8lbfft)
–Mount and tighten the right handlebar weight.
700214-01
–Position the operating elements on the left half of the handlebar.
Info
Position holding lugin bore.
700215-01
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
–Position all operating elements exactly on the handlebar. Tighten all screws.

SET‑UP 4
700216-01
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
700217-01
–Mount the reflector.
–Recharge the battery. ( S. 6)
–Stow away the tool set under the seat.
700211-01
–Remove the protective plastic.
–Carefully loosen and remove the tensioning belt over the link fork.
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 of the palette.
–Fit the front spoiler. ( S. 8)
–Fill up with fuel. ( S. 8)
–Print out the current PDI form found on KTMDEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( S. 7)

WORK 5
3WORK
3.1Removing the seat
700131-01
–Insert the ignition key in the seat lockand turn it 45° counterclockwise.
–Lift up the seat at the rear, pull it back and remove from above.
3.2Mounting the seat
700199-01
–Suspend the seat on the screw, press the rear downwards and at the same time
push it forwards. The two projectionsmust be inserted into the frame.
–Push the locking pininto the lock housing and push the back of the seat down
until the locking pin locks in place with an audible click.
–Remove the ignition key from the seat lock.
–Finally, check that the seat is correctly mounted.
3.3Reinstalling the fuel tank
–Remove the seat. ( S. 5)
700159-01
–Remove screw.
Info
The fuel lines do not need to be disconnected.
700160-10
–Lay a clothover the subframe and straighten the steering.
–Carefully raise the fuel tank and move it backwards.
–Place the fuel tank on the vehicle so that the left spoiler is still lying on the com-
pensating tank(see illustration). Place a clothbetween the compensating
tank and the spoiler to prevent damage.
3.4Positioning the fuel tank
700160-11
–Remove the clothfrom between the compensating tank and the spoiler.

WORK 6
700161-01
–Carefully move the fuel tank forwards and lower it.
–Mount and tighten screwwith bearing sleeveand rubber bushing. Check
fuel tank for tight fitting.
Guideline
Screw, fuel tank bracket M8 15Nm
(11.1lbfft)
–Check the routing of the fuel hoses.
–Mount the seat. ( S. 5)
3.5Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only 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 doctor.
Warning
Environmental hazard Components and battery acid are a danger to the environment.
–Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Environmental hazard Problem materials cause environmental damage.
–Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
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.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all power-consuming components and switch off the engine.
–Reinstall the fuel tank. ( S. 5)
–Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.

WORK 7
100151-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger(58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid.
Charge the battery according to the instructionson the battery casing.
–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
–Position the fuel tank. ( S. 5)
–Mount the seat. ( S. 5)
–Set the clock. ( S. 7)
3.6Setting the clock
Condition
The motorcycle is standing.
700115-10
–Switch on the ignition by turning the ignition key to the position 
(690DUKEUSA).
–Press theMODEbutton several times until theODO display mode is active.
–Keep theMODEbutton and theSETbutton pressed simultaneously.
The time begins to flash.
–Press theMODEbutton to adjust the hour.
–Press theSETbutton to adjust the minute.
–Keep theMODEbutton and theSETbutton pressed simultaneously.
The time is set.
3.7Setting kilometers or miles
Info
If you change the unit, the ODO value is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is standing.
700120-01
–Switch on the ignition by turning the ignition key to the position 
(690DUKEUSA).
–Press theMODEbutton several times until theODO display mode is active.
–Keep the MODEbutton pressed until the display mode changes fromKm/h to Mph or
from Mph to Km/h.
Guideline
Activation duration of MODEbutton 10s

WORK 8
3.8Fitting front spoiler
300028-01
–Position the front spoiler side parts to the center part and latch in.
–Fit the rubber grommets.
300026-10
–Position the front spoiler to the retaining bracket. Fit screwswith bushes, but
do not tighten yet.
Info
Do not forget the insulating washer on the retaining bracket.
300027-10
–Fit and tighten screwwith a flange adapter on both sides.
Guideline
Screw, bug spoiler M6 7Nm (5.2lbfft)
–Fully tighten screws.
Guideline
Screw, bug spoiler M6 7Nm (5.2lbfft)
3.9Refueling
Danger
Fire hazard Fuel can easily catch fire.
–Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
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.
Info
This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded
fuel only.

WORK 9
100120-10
–Switch off engine.
–Open the filler cap.
–Fill the fuel tank with fuel up to measurement.
Guideline
Measurement of50mm (1.97in)
Fuel tank content 13.5l
(3.57USgal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( S. 12)
–Close the filler cap.
100121-10
–Press theSETfunction button for 2 seconds.
The fuel level warning lampswitches off. TRIPFis set to 0 and appears in
the previous display mode.
Info
If you do not press theSETfunction button, the reset takes place auto-
matically after about 3 minutes.

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 10
4TECHNICAL DATA - CHASSIS T IGHTENING TORQUES
Screw, combination instrument 1Nm (0.7lbfft) –
Screw, combination instrument holder 1Nm (0.7lbfft) –
Screw, side stand switch M4 2Nm (1.5lbfft) Loctite®243™
Remaining screws, chassis M5 4Nm (3lbfft) –
Screw, pressure regulator M5 4Nm (3lbfft) –
Screw, footbrake pedal foothold M5 6Nm (4.4lbfft) Loctite®243™
Screw, plastic clamp of brake line on
fork leg
M5 2Nm (1.5lbfft) –
Screw, fuel pump M5 4Nm (3lbfft) –
Screw, fuel level indicator M5 3Nm (2.2lbfft) –
Screw, side cover M5 2Nm (1.5lbfft) –
Screw, seat lock M5 3Nm (2.2lbfft) Loctite®222
Screw, starter cable on starter M5 3Nm (2.2lbfft) –
Remaining nuts, chassis M6 15Nm (11.1lbfft) –
Remaining screws on fuel tank M6 6Nm (4.4lbfft) –
Remaining screws, chassis M6 10Nm (7.4lbfft) –
Screw, brake fluid reservoir of rear
brake
M6 5Nm (3.7lbfft) –
Screw, battery holder M6 3Nm (2.2lbfft) –
Screw, bug spoiler M6 7Nm (5.2lbfft) –
Screw, footbrake cylinder M6 10Nm (7.4lbfft) Loctite®243™
Screw, horn M6 6Nm (4.4lbfft) Loctite®243™
Screw, license plate holder M6 8Nm (5.9lbfft) –
Screw, ball joint of push rod on foot-
brake cylinder
M6 10Nm (7.4lbfft) Loctite®243™
Screw, lower radiator bracket M6 5Nm (3.7lbfft) –
Screw, fuel tap M6 Tightening sequence:
tighten in parallel
6Nm (4.4lbfft)
–
Screw, magnetic holder on side stand M6 10Nm (7.4lbfft) Loctite®243™
Screw, voltage regulator/rectifier M6 8Nm (5.9lbfft) –
Screw, SLS valve M6 6Nm (4.4lbfft) –
Screw, headlight mask M6 5Nm (3.7lbfft) –
Screw, side stand bracket M6 10Nm (7.4lbfft) Loctite®243™
Screw, control unit holder M6 3Nm (2.2lbfft) –
Nut, rear sprocket screw M8 35Nm (25.8lbfft) Loctite®243™
Nut, manifold on cylinder head M8 25Nm (18.4lbfft) Copper paste
Remaining nuts, chassis M8 30Nm (22.1lbfft) –
Remaining screws, chassis M8 25Nm (18.4lbfft) –
Screw, rear brake disc (690DUKEEU,
690DUKEAUS/UK, 690DUKEJP,
690DUKEUSA)
M8 30Nm (22.1lbfft) Loctite®243™
Screw, front brake disc
(690DUKEEU, 690DUKEAUS/UK,
690DUKEJP, 690DUKEUSA)
M8 30Nm (22.1lbfft) Loctite®243™
Screw, main silencer fixation M8 25Nm (18.4lbfft) –
Screw, spring holder on side stand
bracket
M8 15Nm (11.1lbfft) Loctite®243™
Screw, rear footrest bracket M8 25Nm (18.4lbfft) Loctite®243™
Screw, top triple clamp M8 12Nm (8.9lbfft) –
Screw, bottom triple clamp M8 15Nm (11.1lbfft) –
Screw, fork stub M8 15Nm (11.1lbfft) –
Screw, steering stem M8 20Nm (14.8lbfft) –
Screw, handrail M8 6Nm (4.4lbfft) –

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 11
Screw, fuel tank bracket M8 15Nm (11.1lbfft) –
Screw, manifold on main silencer M8 25Nm (18.4lbfft) Copper paste
Screw, handlebar clamp M8 20Nm (14.8lbfft) –
Screw, upper subframe M8 35Nm (25.8lbfft) Loctite®243™
Screw, side stand bracket M8 25Nm (18.4lbfft) Loctite®243™
Screw, linkage bracket, front engine
bracket
M8 25Nm (18.4lbfft) Loctite®243™
Screw, ignition lock M8 Loctite®243™
Screw, front brake caliper M10x1.25 45Nm (33.2lbfft) Loctite®243™
Screw, lower subframe M10x1.25 45Nm (33.2lbfft) Loctite®243™
Engine carrying screw M10 45Nm (33.2lbfft) Loctite®243™
Remaining nuts, chassis M10 50Nm (36.9lbfft) –
Remaining screws, chassis M10 45Nm (33.2lbfft) –
Screw, top shock absorber M10 45Nm (33.2lbfft) Loctite®243™
Screw, bottom shock absorber M10 45Nm (33.2lbfft) Loctite®243™
Screw, handlebar support M10 20Nm (14.8lbfft) –
Screw, side stand M10 35Nm (25.8lbfft) Loctite®243™
Lambda probe M12x1.25 24.5Nm (18.07lbfft) –
Nut, frame to linkage lever M14x1.5 100Nm (73.8lbfft) –
Nut, linkage lever to rocker arm M14x1.5 100Nm (73.8lbfft) –
Nut, linkage lever on swingarm M14x1.5 100Nm (73.8lbfft) –
Nut, swingarm pivot M16x1.5 100Nm (73.8lbfft) –
Screw, steering head M20x1.5 12Nm (8.9lbfft) –
Adjusting ring of swingarm bearing M24x1.5 25Nm (18.4lbfft) –
Screw, front wheel spindle M24x1.5 40Nm (29.5lbfft) –
Nut, rear wheel spindle M25x1.5 90Nm (66.4lbfft) –

SUBSTANCES 12
5SUBSTANCES
Super unleaded (ROZ 95 / RON 95 / PON 91)
according to
–DINEN228 (ROZ 95 / RON 95 / PON 91)

*3211338en*
3211338en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
04/2008 Photo Mitterbauer