KTM 690Supermoto R User manual

OWNER'S MANUAL 2008
690bSUPERMOTObRbUSA
ART. NO. 3211304en

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 Dealer's stamp
Engine number ( P. 23)
Key number ( P. 23)
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
© 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

CONTENTS 3
&217(176
MEANS OF REPRESENTATION ............................................... 6
IMPORTANT NOTES............................................................... 7
Overview of warning labels................................................. 10
VIEW OF VEHICLE................................................................ 18
View of vehicle, front left side............................................ 18
View of vehicle, rear right side ........................................... 20
LOCATION OF SERIAL NUMBERS ......................................... 22
Chassis number/type label................................................. 22
Key number ..................................................................... 23
Engine number................................................................. 23
Fork part number.............................................................. 24
Shock absorber part number.............................................. 24
OPERATING ELEMENTS....................................................... 25
Clutch lever ..................................................................... 25
Hand brake lever .............................................................. 25
Light switch..................................................................... 26
Headlight flasher switch.................................................... 26
Flasher switch.................................................................. 27
Horn ............................................................................... 27
Ignition/steering lock ........................................................ 28
Emergency OFF switch...................................................... 28
Electric starter button ....................................................... 29
Combination instrument.................................................... 29
Combination instrument - function buttons ......................... 30
Combination instrument - tachometer................................. 30
Combination instrument - control lamps ............................. 31
Combination instrument - Display ...................................... 32
Combination instrument - speed display ............................. 33
Setting kilometers or miles ................................................ 33
Combination instrument - time .......................................... 34
Setting the clock .............................................................. 34
Combination instrument -bODO display ............................... 35
Combination instrument - setting/resettingbTRIPb1 display.... 35
Combination instrument - setting/resettingbTRIPb2 display.... 36
Combination instrument -bTRIPbF display ............................ 37
Combination instrument - coolant temperature indicator ...... 37
Opening filler cap............................................................. 38
Closing filler cap .............................................................. 38
Fuel taps ......................................................................... 39
Handrails......................................................................... 39
Seat lock ......................................................................... 40
OWNER'S MANUAL.......................................................... 40
Tool set ........................................................................... 41
Passenger footrests........................................................... 41
Shift lever........................................................................ 42
Foot brake pedal .............................................................. 43
Side stand ....................................................................... 43
TIPS ON PUTTING INTO OPERATION .................................... 44
Advice on first use............................................................ 44
Running in the engine....................................................... 45
Loading the vehicle .......................................................... 46
RIDING INSTRUCTIONS ....................................................... 48
Checks before putting into operation .................................. 48
Starting ........................................................................... 49
Starting up ...................................................................... 51
Shifting, riding................................................................. 51
Braking ........................................................................... 54
Stopping, parking ............................................................. 55

CONTENTS 4
Refueling......................................................................... 57
GREASING AND SERVICE TABLE.......................................... 59
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................ 59
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................... 61
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 62
Jacking up front of motorcycle ........................................... 62
Taking front from work stand ............................................. 62
Jacking up rear of motorcycle ............................................ 63
Take the rear from the work stand. ..................................... 63
Fork/shock absorber.......................................................... 64
Adjusting compression damping of fork .............................. 64
Adjusting rebound damping of fork..................................... 65
Compression damping of shock absorber............................. 66
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 66
Adjusting high-speed compression damping of the shock
absorber .......................................................................... 67
Adjusting rebound damping of the shock absorber ............... 68
Bleeding fork legs............................................................. 69
Checking chain dirt .......................................................... 70
Cleaning the chain............................................................ 70
Checking the chain tension ............................................... 71
Adjusting chain tension..................................................... 72
Checking rear sprocket / engine sprocket for wear ................ 74
Checking chain wear......................................................... 75
Checking brake discs ........................................................ 76
Adjusting basic position of handbrake lever......................... 77
Checking front brake fluid level.......................................... 77
Adding brake fluid for front brakebx.................................. 78
Brake linings.................................................................... 79
Checking the front brake linings......................................... 80
Checking free play of foot brake lever ................................. 81
Checking rear brake fluid level........................................... 81
Topping up brake fluid of rear brakebx.............................. 82
Checking rear brake linings ............................................... 83
Removing front wheelbx.................................................. 84
Fitting front wheelbx....................................................... 85
Removing rear wheelbx.................................................... 86
Fitting rear wheelbx........................................................ 87
Checking the rear hub rubber dampersbx.......................... 89
Checking tire condition ..................................................... 90
Checking tire air pressure.................................................. 91
Removing the seat ............................................................ 92
Mounting the seat ............................................................ 92
Reinstalling the fuel tank .................................................. 93
Positioning the fuel tank ................................................... 94
Removing the batterybx................................................... 95
Installing the batterybx.................................................... 96
Recharging the batterybx................................................. 96
Changing the main fuse .................................................... 98
Changing fuses of individual power consumers .................. 100
Removing headlight mask with headlight .......................... 102
Refitting the headlight mask with the headlight................. 103
Changing headlight bulb ................................................. 104
Changing the parking lamp.............................................. 105
Changing flasher bulb ..................................................... 106
Checking headlamp setting.............................................. 107

CONTENTS 5
Adjusting the headlight range .......................................... 108
Cooling system............................................................... 109
Checking antifreeze and coolant level ............................... 109
Checking the coolant level............................................... 112
Draining coolantbx........................................................ 113
Filling/bleeding the cooling systembx.............................. 114
Adjusting basic position of clutch lever............................. 116
Checking/correcting fluid level of hydraulic clutch ............. 117
Checking play in gas Bowden cable .................................. 117
Adjusting play in gas Bowden cablebx............................. 118
Adjusting the handlebar anglebx..................................... 119
Checking engine oil level................................................. 119
Changing engine oil and oil filter, cleaning oil
screensbx..................................................................... 120
Draining engine oilbx.................................................... 120
Removing the oil filterbx................................................ 122
Mounting oil filterbx...................................................... 123
Cleaning oil screensbx................................................... 123
Filling up with engine oilbx............................................ 125
Topping up engine oil ..................................................... 126
TROUBLESHOOTING.......................................................... 128
FLASHING CODE ............................................................... 131
CLEANING......................................................................... 134
Cleaning motorcycle ....................................................... 134
CONSERVATION FOR WINTER OPERATION ......................... 136
Conservation for winter operation ..................................... 136
STORAGE .......................................................................... 137
Storage.......................................................................... 137
Putting into operation after storage .................................. 138
TECHNICAL DATA - ENGINE............................................... 139
Capacity - engine oil ....................................................... 140
Capacity - coolant........................................................... 140
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 141
TECHNICAL DATA - CHASSIS ............................................. 144
Lighting equipment ........................................................ 145
Capacity - fuel................................................................ 146
TECHNICAL DATA - FORK................................................... 147
TECHNICAL DATA - SHOCK ABSORBER .............................. 148
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 150
SUBSTANCES.................................................................... 154
AUXILIARY SUBSTANCES................................................... 157
STANDARDS...................................................................... 159
INDEX ............................................................................... 160

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/or 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.
The currentbKTMbPowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Transport
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದAlways place the vehicle on a firm and even surface.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದDo not place the vehicle where there are flammable or explosive substances.
ದSwitch off the engine and remove the ignition key.
ದUse 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

IMPORTANT NOTES 10
Overview of warning labels
500230-10

IMPORTANT NOTES 11
1 Type label, Canada
2 Type label, USA
3 Information, emission control
4 Information, noise emission
5 Information, suspension setting
6 Information, chain tension
7 Information, fuel evaporation system
8 Information, putting into operation
700203-01
Type label, Canada

IMPORTANT NOTES 12
700205-01
Type label, USA
500231-01
Information, emission control

IMPORTANT NOTES 13
500232-01
Information, noise emission
700208-01
Information, suspension setting

IMPORTANT NOTES 14
700207-01
Information, chain tension
700209-01
Information, fuel evaporation system
700210-01
Information, putting into operation

IMPORTANT NOTES 15
Notes/warning notes
Pay attention to the specified notes and warnings.
Info
Various notes and warning labels are attached to the vehicle. Do not remove any notes or 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
ದRead 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 16
ದThe owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remady campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM
North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1ದ888ದ327ದ4236 or visit the website www.nhtsa.dot.gov, or
write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other informa-
tion about motor vehicle safety from the Hotline.
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telephone: (440) 985ದ3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Kanada
Telephone: (450) 441ದ4451 x 39
www.ktmcanada.com
Tampering warning
Tampering with noise control system prohibited.Federal law prohibits the following acts or causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur-
chaser or while it is in use, or

IMPORTANT NOTES 17
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
1 Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
Warning, operating noise
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the
owner may become subject to penalties under state and local ordinances.
Consumer rights
Limited warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telephone: (440) 985ದ3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7, Kanada
Telephone: (450) 441ದ4451 x 39
www.ktmcanada.com
Your rights may vary, please refer to the applicable state laws.

VIEW OF VEHICLE 18
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
View of vehicle, front left side
500233-10