KTM 690 Supermoto Limited Edition EU 2009 User manual

OWNER'S MANUAL 2009
690 Supermoto Limited Edition EU
Art. no. 3211364en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
We would like to congratulate you on deciding to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcy-
cle that will give you a great deal of pleasure during your ownership if you service and maintained it accordingly.
We wish you a lot of enjoyment in riding this 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 contained the latest information for this model at the time of going to print. Minor differences due to developments in
design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle AG 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 illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not form part of the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2009 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)
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

TABLE OF CONTENTS 3
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................... 6
IMPORTANT INFORMATION ................................................... 7
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left side............................................ 12
View of vehicle, rear right .................................................. 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
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Light switch ..................................................................... 20
Headlight flasher switch.................................................... 20
Turn signal switch ............................................................ 21
Horn button ..................................................................... 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 - indicator lamps........................... 25
Combination instrument - display....................................... 26
Combination instrument - speedometer............................... 27
Setting kilometers or miles ................................................ 27
Combination instrument - time .......................................... 28
Setting the clock .............................................................. 28
Combination instrument - display ODO ............................... 29
Combination instrument - setting/resetting TRIP 1............... 29
Combination instrument - setting/resetting TRIP 2............... 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 lever................................................................ 37
Side stand ....................................................................... 37
GENERAL TIPS AND HINTS ON PREPARING FOR USE........... 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

TABLE OF CONTENTS 4
SERVICE SCHEDULE............................................................ 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 FRAME AND ENGINE.................... 57
Jacking up front of motorcycle ........................................... 57
Taking the front from the work stand .................................. 57
Jacking up rear of motorcycle ............................................ 58
Taking the rear from the workstand .................................... 58
Fork/shock absorber.......................................................... 59
Adjusting the rebound damping of the fork.......................... 59
Adjusting the rebound damping of the shock absorber.......... 60
Bleeding the fork legs ....................................................... 61
Checking the chain for dirt ................................................ 62
Cleaning the chain............................................................ 62
Checking the chain tension ............................................... 63
Adjusting the chain tension ............................................... 64
Checking rear sprocket / engine sprocket for wear ................ 66
Checking chain wear......................................................... 67
Checking the brake discs................................................... 68
Adjusting basic position of hand brake lever........................ 69
Checking the front brake fluid level .................................... 69
Adding front brake fluid x............................................... 70
Checking the front brake linings......................................... 72
Checking free play of foot brake lever ................................. 72
Checking rear brake fluid level........................................... 73
Adding rear brake fluid x................................................ 74
Checking the rear brake linings.......................................... 75
Removing the front wheel x............................................. 76
Installing the front wheel x.............................................. 77
Removing rear wheel x.................................................... 78
Installing the rear wheel x............................................... 79
Checking the rear hub rubber dampers x.......................... 81
Checking the tire condition................................................ 82
Checking the tire pressure................................................. 84
Checking the spoke tension ............................................... 85
Removing the seat............................................................ 86
Mounting the seat ............................................................ 86
Reinstalling the fuel tank .................................................. 87
Positioning the fuel tank ................................................... 88
Removing the battery x................................................... 89
Installing the battery x.................................................... 90
Recharging the battery x................................................. 90
Changing the main fuse .................................................... 92
Changing the fuses of individual power consumers............... 93
Removing headlight mask with headlight ............................ 95
Refitting the headlight mask with the headlight................... 96
Changing the headlight bulb.............................................. 97
Changing the parking light bulb ......................................... 98
Changing the turn signal bulb............................................ 99
Checking the headlight setting......................................... 100
Adjusting the headlight range .......................................... 100
Cooling system ............................................................... 101
Checking the antifreeze and coolant level ......................... 102
Checking the coolant level............................................... 105
Draining the coolant x.................................................. 106
Filling/bleeding the cooling system x.............................. 107

TABLE OF CONTENTS 5
Adjusting basic position of clutch lever............................. 109
Checking the basic position of the shift lever..................... 110
Adjusting the basic position of the shift lever x............... 111
Checking/rectifying the fluid level of the hydraulic clutch ... 112
Checking the play in the throttle cable.............................. 112
Adjusting the play in the throttle cable x........................ 113
Adjusting the handlebar angle x.................................... 114
Checking the engine oil level ........................................... 114
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 115
Draining the engine oil x............................................... 115
Removing the oil filter x................................................ 117
Installing the oil filter x................................................ 118
Cleaning the oil screens x............................................. 118
Refilling with engine oil x............................................. 120
Adding engine oil ........................................................... 121
TROUBLESHOOTING.......................................................... 123
BLINK CODE ..................................................................... 126
CLEANING......................................................................... 131
Cleaning motorcycle ....................................................... 131
PROTECTIVE TREATMENT FOR WINTER OPERATION........... 133
Protective treatment for winter operation .......................... 133
STORAGE .......................................................................... 134
Storage.......................................................................... 134
Putting into operation after storage .................................. 135
TECHNICAL DATA - ENGINE............................................... 136
Capacity - engine oil ....................................................... 137
Capacity - coolant........................................................... 137
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 138
TECHNICAL DATA - CHASSIS ............................................. 141
Lighting equipment ........................................................ 142
Capacity - fuel................................................................ 143
TECHNICAL DATA - FORK................................................... 144
TECHNICAL DATA - SHOCK ABSORBER .............................. 145
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 146
OPERATING SUBSTANCES................................................. 150
AUXILIARY SUBSTANCES................................................... 153
STANDARDS...................................................................... 155
INDEX ............................................................................... 156

MEANS OF REPRESENTATION 6
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).
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.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT INFORMATION 7
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 ser-
vice schedule 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 work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth-
erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes
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 INFORMATION 8
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
Some spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe-
ses. Example: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.

IMPORTANT INFORMATION 9
–Switch off the engine and remove the ignition key.
–Use 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.
Notes/warnings
Pay close attention to the notes/warning.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.

IMPORTANT INFORMATION 10
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that will possibly lead to light injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful 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 motor-
cycle.
–The 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
3.1View of vehicle, front left side
600882-10

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
3.2View of vehicle, rear right
600881-10

VIEW OF VEHICLE 15
1 Seat lock
2 Light switch, headlight flasher switch, turn signal switch, horn
3 Filler cap
4 Emergency OFF switch, electric starter button
5 Hand brake lever
6 Chassis number, type label
7 Brake caliper, rear
8 Passenger footrests
9 Foot brake lever
10 Level viewer, engine oil
11 Right fuel tap

LOCATION OF SERIAL NUMBERS 16
4.1Chassis number/type label
500006-01
The chassis number is stamped on the right of the steering head.
The type label is on the right of the frame behind the steering head.
4.2Key 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
4.3Engine number
500001-01
The engine number is stamped on the left side of the engine under the engine sprocket.
4.4Fork part number
100184-10
The fork part number is stamped on the inner side of the fork stub.

LOCATION OF SERIAL NUMBERS 18
4.5Shock absorber part number
100185-10
The shock absorber part number is stamped on the top of the shock absorber above the
adjusting ring on the engine side.