KTM 690 DUKE R EU User manual

OWNER'S MANUAL 2008
690DUKE
ART. NO. 3211248en

DEAR KTM CUSTOMER 1
'($5 .70 &86720(5
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number/type label ( P. 16) Dealer's stamp
Engine number ( P. 17)
Key number ( P. 16)
The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small
deviations arising from further development in design and construction.
All specifications are not binding. KTM Sportmotorcycle AG in particular 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, as well as printing and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2007 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

CONTENTS 3
&217(176
MEANS OF REPRESENTATION ............................................... 6
IMPORTANT NOTES............................................................... 7
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left side............................................ 12
View of vehicle, rear right side ........................................... 14
LOCATION OF SERIAL NUMBERS ......................................... 16
Chassis number/type label................................................. 16
Key number ..................................................................... 16
Engine number................................................................. 17
Fork part number.............................................................. 17
Shock absorber part number.............................................. 18
OPERATING ELEMENTS....................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Light switch..................................................................... 20
Headlight flasher switch.................................................... 20
Flasher switch.................................................................. 21
Horn ............................................................................... 21
Ignition/steering lock ........................................................ 22
Emergency OFF switch...................................................... 22
Electric starter button ....................................................... 23
Combination instrument.................................................... 23
Combination instrument - function buttons ......................... 24
Combination instrument - tachometer................................. 24
Combination instrument - control lamps ............................. 25
Combination instrument - Display ...................................... 26
Combination instrument - speed display ............................. 27
Setting kilometers or miles ................................................ 27
Combination instrument - time .......................................... 28
Setting the clock .............................................................. 28
Combination instrument -ODO display ............................... 29
Combination instrument - setting/resettingTRIP1 display.... 29
Combination instrument - setting/resettingTRIP2 display.... 30
Combination instrument -TRIPF display ............................ 31
Combination instrument - coolant temperature indicator ...... 31
Opening filler cap............................................................. 32
Closing filler cap .............................................................. 32
Fuel taps ......................................................................... 33
Handrails......................................................................... 33
Seat lock ......................................................................... 34
OWNER'S MANUAL.......................................................... 34
Tool set ........................................................................... 35
Passenger footrests........................................................... 35
Shift lever........................................................................ 36
Foot brake pedal .............................................................. 37
Side stand ....................................................................... 37
TIPS ON PUTTING INTO OPERATION .................................... 38
Advice on first use............................................................ 38
Running in the engine....................................................... 39
Loading the vehicle .......................................................... 40
RIDING INSTRUCTIONS ....................................................... 42
Checks before putting into operation .................................. 42
Starting ........................................................................... 43
Starting up ...................................................................... 45
Shifting, riding................................................................. 45
Braking ........................................................................... 48
Stopping, parking ............................................................. 49
Refueling......................................................................... 51

CONTENTS 4
GREASING AND SERVICE TABLE .......................................... 53
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................ 53
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................... 55
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 56
Jacking up front of motorcycle ........................................... 56
Taking front from work stand ............................................. 56
Jacking up rear of motorcycle ............................................ 57
Take the rear from the work stand. ..................................... 57
Fork/shock absorber.......................................................... 58
Adjusting compression damping of fork .............................. 58
Adjusting rebound damping of fork..................................... 59
Compression damping of shock absorber............................. 60
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 60
Adjusting high-speed compression damping of the shock
absorber .......................................................................... 61
Adjusting rebound damping of the shock absorber ............... 62
Bleeding fork legs............................................................. 63
Checking chain dirt .......................................................... 64
Cleaning the chain............................................................ 64
Checking the chain tension ............................................... 65
Adjusting chain tension..................................................... 66
Checking rear sprocket / engine sprocket for wear ................ 68
Checking chain wear......................................................... 69
Checking brake discs ........................................................ 70
Adjusting basic position of handbrake lever......................... 71
Checking brake fluid level of front brake ............................. 71
Topping up brake fluid of front brakex............................. 72
Brake linings.................................................................... 73
Checking the front brake linings......................................... 74
Checking free play of foot brake lever ................................. 75
Checking rear brake fluid level........................................... 75
Topping up brake fluid of front brakex............................. 76
Checking rear brake linings ............................................... 78
Removing front wheelx.................................................. 78
Fitting front wheelx....................................................... 80
Removing rear wheelx.................................................... 81
Fitting rear wheelx........................................................ 82
Checking the rear hub rubber dampersx.......................... 84
Tire condition checking..................................................... 85
Checking tire air pressure.................................................. 86
Removing the seat ............................................................ 87
Mounting the seat ............................................................ 87
Reinstalling the fuel tank .................................................. 88
Positioning the fuel tank ................................................... 89
Removing the batteryx................................................... 90
Installing the batteryx.................................................... 92
Recharging the batteryx................................................. 94
Changing the main fuse .................................................... 96
Changing fuses of individual power consumers .................... 97
Adjusting the engine characteristics ................................... 99
Removing headlight mask with headlight .......................... 101
Refitting the headlight mask with the headlight................. 103
Changing the low beam bulb............................................ 104
Changing the high beam bulb .......................................... 106
Changing the parking light bulb ....................................... 108
Changing the flasher bulb ............................................... 109

CONTENTS 5
Checking the low beam headlight adjustment.................... 110
Checking the high beam headlight adjustment .................. 111
Adjusting the light range of the low beam headlight........... 112
Adjusting the light range of the high beam headlight ......... 114
Cooling system............................................................... 116
Checking antifreeze and coolant level ............................... 116
Checking the coolant level............................................... 119
Draining coolantx........................................................ 120
Filling/bleeding the cooling systemx.............................. 121
Adjusting basic position of clutch lever............................. 123
Checking/correcting fluid level of hydraulic clutch ............. 124
Checking play in gas Bowden cable .................................. 124
Adjusting play in gas Bowden cablex............................. 125
Adjusting the handlebar anglex..................................... 126
Checking engine oil level................................................. 126
Changing engine oil and oil filter, cleaning oil
screensx..................................................................... 127
Draining engine oilx.................................................... 127
Removing the oil filterx................................................ 129
Mounting oil filterx...................................................... 131
Cleaning oil screensx................................................... 131
Filling up with engine oilx............................................ 133
Topping up engine oil ..................................................... 134
TROUBLESHOOTING.......................................................... 136
FLASHING CODE ............................................................... 139
CLEANING......................................................................... 142
Cleaning motorcycle ....................................................... 142
CONSERVE FOR WINTER OPERATION................................. 144
Conservation for winter operation ..................................... 144
STORAGE .......................................................................... 145
Storage.......................................................................... 145
Putting into operation after storage .................................. 146
TECHNICAL DATA - ENGINE............................................... 147
Capacity - engine oil ....................................................... 148
Capacity - coolant........................................................... 148
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 149
TECHNICAL DATA - CHASSIS ............................................. 152
Lighting equipment ........................................................ 153
Capacity - fuel................................................................ 154
TECHNICAL DATA - FORK................................................... 155
TECHNICAL DATA - SHOCK ABSORBER .............................. 156
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 158
SUBSTANCES.................................................................... 162
AUXILIARY SUBSTANCES................................................... 165
STANDARDS...................................................................... 167
INDEX ............................................................................... 168

MEANS OF REPRESENTATION 6
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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).
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.
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.
Eigenname Indicates a proprietary name.
Name®Identifies a protected name.
Marke™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 7
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Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in
the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage
resulting from manipulations and alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT NOTES 8
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop.
KTM accepts no liability for other products and any resulting damage or loss.
For the latestKTMPowerParts for your vehicle, see
International KTM Website: http://www.ktm.com
Transport
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥAlways place the vehicle on a firm and even surface.
Note
Fire hazardಗSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ಥDo not place the vehicle where there are flammable or explosive substances.
ಥSwitch off the engine and remove the ignition key.
ಥUse straps or other suitable devices to secure the motorcycle against accidents or falling over.
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 potential
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. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.

IMPORTANT NOTES 9
Warning notes
In your own interest, read the specified warning notes.
Info
Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may not
recognize dangers and may therefore be injured.
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Caution
Danger that could possibly lead to slight injuries.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
OWNER'S MANUAL
ಥRead this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you
operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you
can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

IMPORTANT NOTES 10
ಥThe owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

11

VIEW OF VEHICLE 12
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View of vehicle, front left side
700132-01

VIEW OF VEHICLE 13
1 Combination instrument
2 Rear mirror
3 Clutch lever
4 Seat
5 Handrail
6 Front brake caliper
7 Left fuel tap
8 Shift lever
9 Engine number
10 Side stand

VIEW OF VEHICLE 14
View of vehicle, rear right side
700133-01

VIEW OF VEHICLE 15
1 Seat lock
2 Light switch, headlight flasher switch, indicator switch, horn
3 Filler cap
4 Emergency OFF switch, electric starter button
5 Hand brake lever
6 Chassis number, type label
7 Rear brake caliper
8 Passenger footrests
9MapಣSelectSwitch
10 Foot brake pedal
11 Engine oil level viewer
12 Right fuel tap

LOCATION OF SERIAL NUMBERS 16
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Chassis number/type label
500006-01
The chassis numberis stamped on the steering head on the right.
The type labelis located under the chassis number.
Key number
100179-10
The key numbercan be found on theKEYCODECARD.
Info
You need the key number to order a spare key. Keep theKEYCODECARD in a safe
place.

LOCATION OF SERIAL NUMBERS 17
Engine number
700125-01
The engine numberis stamped on the left side of the engine under the engine sprocket.
Fork part number
700126-01
The fork part numberis stamped on the inner side of the fork stub.

LOCATION OF SERIAL NUMBERS 18
Shock absorber part number
700128-01
The shock absorber part numberis stamped on the top of the shock absorber above the
adjusting ring toward the rear.