KTM 690 DUKE Manual

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OWNER'S MANUAL 2009

690 DUKE EU

690 DUKE AUS/UK

690 DUKE JP

ART. NO. 3211370en

DEAR KTM CUSTOMER

Congratulations on your decision to buy 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. Slight deviations resulting from continuing development and design of our motorcycles cannot however be completely excluded.

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 belong to the regular scope of delivery.

DEAR KTM CUSTOMER

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

CONTENTS

MEANS OF REPRESENTATION ...............................................	6
IMPORTANT NOTES...............................................................	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
Flasher 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 pedal ..............................................................	37
Side stand .......................................................................	37
GENERAL TIPS AND HINTS 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

CONTENTS

Refueling.........................................................................	51
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 CHASSIS AND ENGINE.................	56
Jacking up front of motorcycle ...........................................	56
Taking front from work stand .............................................	56
Jacking up rear of motorcycle ............................................	57
Taking the rear from the workstand ....................................	57
Fork/shock absorber..........................................................	58
Adjusting the compression damping of the fork ...................	58
Adjusting the rebound damping of the fork..........................	59
Compression damping of the shock absorber .......................	60
Adjusting the low-speed compression damping of the shock
absorber ..........................................................................	60
Adjusting the high-speed compression damping of the
shock absorber .................................................................	61
Adjusting the rebound damping of the shock absorber..........	62
Bleeding the fork legs .......................................................	63
Checking chain dirt ..........................................................	64
Cleaning the chain............................................................	64
Checking the chain tension ...............................................	65
Adjusting the 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 the front brake fluid level ....................................	71

Adding front brake fluid x...............................................	72
Checking the front brake linings.........................................	73
Checking free play of foot brake lever .................................	74
Checking rear brake fluid level...........................................	75
Adding rear brake fluid x................................................	76
Checking the rear brake linings ..........................................	77
Removing front wheel x..................................................	78
Installing the front wheel x..............................................	79
Removing rear wheel x....................................................	80
Installing the rear wheel x...............................................	81
Checking the rear hub rubber dampers x..........................	83
Checking the tire condition................................................	84
Checking tire air pressure..................................................	85
Removing the seat ............................................................	86
Mounting the seat ............................................................	87
Reinstalling the fuel tank ..................................................	87
Positioning the fuel tank ...................................................	88
Removing the battery x...................................................	89
Installing the battery x....................................................	91
Recharging the battery x.................................................	93
Changing the main fuse ....................................................	95
Changing the fuses of power consumers..............................	96
Adjusting the engine characteristic.....................................	98
Removing headlight mask with headlight ..........................	100
Installing the headlight mask with the headlight................	102
Changing the low beam bulb............................................	103
Change the high beam bulb.............................................	106
Changing the parking light bulb .......................................	108
Changing the flasher bulb ...............................................	109

CONTENTS

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 .........	113
Cooling system ...............................................................	115
Checking antifreeze and coolant level ...............................	115
Checking the coolant level...............................................	118
Draining the coolant x..................................................	119
Filling/bleeding the cooling system x..............................	120
Adjusting basic position of clutch lever.............................	122
Checking/rectifying the fluid level of the hydraulic clutch ...	123
Checking play in gas Bowden cable ..................................	124
Adjusting the play in the gas Bowden cable x..................	125
Checking engine oil level.................................................	125
Changing the engine oil and filter, cleaning the oil
screens x.....................................................................	126
Draining the engine oil x...............................................	126
Removing the oil filter x................................................	127
Installing the oil filter x................................................	129
Cleaning the oil screens x.............................................	129
Filling up with engine oil x............................................	131
Adding engine oil ...........................................................	132
TROUBLESHOOTING..........................................................	134
FLASHING CODE ...............................................................	137
CLEANING.........................................................................	142
Cleaning motorcycle .......................................................	142
PROTECTION 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...................................................	166
STANDARDS......................................................................	168
INDEX ...............................................................................	169

MEANS OF REPRESENTATION

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 NOTES

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 service 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; otherwise 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 NOTES

Spare parts, accessories

In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

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 advice 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.

–Switch off the engine and remove the ignition key.

–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT NOTES

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 NOTES

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 motorcycle.

–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.

	VIEW OF VEHICLE	12

	View3.1 of vehicle, front left side

700132-01

VIEW OF VEHICLE

1Combination instrument

2Rear mirror

3Clutch lever

4Seat

5Handrail

6Front brake caliper

7Left fuel tap

8Shift lever

9Engine number

10Side stand

	VIEW OF VEHICLE	14

	View3.2 of vehicle, rear right

700133-01

	VIEW OF VEHICLE		15

1		Seat lock

2		Light switch, headlight flasher switch, indicator switch, horn button

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

9		Map Select switch

10		Foot brake pedal

11		Level viewer, engine oil

12		Right fuel tap

LOCATION OF SERIAL NUMBERS

Chassis4.1 number/type label

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.

500006-01

Key4.2 number

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.

100179-10

LOCATION OF SERIAL NUMBERS

Engine4.3 number

The engine number is stamped on the left side of the engine under the engine sprocket.

700125-01

Fork4.4 part number

The fork part number is stamped on the inner side of the fork stub.

700126-01

LOCATION OF SERIAL NUMBERS

Shock4.5 absorber part number

The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring toward the rear.

700128-01

CONTROLS

Clutch5.1 lever

The clutch lever is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

100114-10

Hand5.2 brake lever

The hand brake lever is fitted on the right side of the handlebar.

The front brake is engaged using the hand brake lever.

500018-01

CONTROLS

Light5.3 switch

The light switch is fitted on the left side of the handlebar.

Possible states

Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on.

High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

500020-01

Headlight5.4 flasher switch

The headlight flasher switch is fitted on the left side of the handlebar.

Possible states

•Headlight flasher switch in neutral position

•Headlight flasher switch pressed – In this position, the headlight flasher (high beam) is actuated.

500020-11

CONTROLS

Flasher5.5 switch

500021-10

The flasher switch is fitted on the left side of the handlebar.

Possible states

Flasher light off

Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

Flasher light, right, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

Horn5.6 button

The horn button is fitted on the left side of the handlebar.

Possible states

•Horn button in neutral position

•Horn button pressed – The horn is operated in this position.

500021-11

CONTROLS

Ignition/steering5.7 lock

600825-01

The ignition/steering lock is in front of the upper triple clamp.

Possible states

Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

Ignition ON – In this position, the ignition circuit is closed and the engine can be started.

Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed.

Emergency5.8 OFF switch

The emergency OFF switch is fitted on the left side of the handlebar.

Possible states

Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.

Emergency OFF switch on – This position is necessary for operation as the ignition circuit is closed.

500022-10

CONTROLS

Electric5.9 starter button

The electric starter button is fitted on the right side of the handlebar.

Possible states

•Electric starter button in basic position

•Electric starter button pressed – In this position, the electric starter is actuated.

500022-11

Combination5.10 instrument

The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas.

Function buttonsTachometer

Indicator lightsDisplay

700116-01

CONTROLS

Combination5.11 instrument - function buttons

You can change the display mode with the MODE button .

Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2).

Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 function (TRIP 2) to 0.0.

Button has no function.

700117-01

Combination5.12 instrument - tachometer

The tachometer shows the engine speed in revolutions per minute.

The red marking shows the excess speed range of the engine.

100118-10

CONTROLS

Combination5.13 instrument - indicator lamps

The indicator lamps offer additional information about the operating state of the motorcycle.

Possible states

The flasher indicator lamp flashes green simultaneously with the flashers

– Flasher light is switched on.

The idle speed indicator lamp lights up green – The transmission is switched to idle.

High beam indicator lamp lights up blue – High beam is switched on.

100119-10

Temperature warning lamp lights up red – Coolant has reached a critical value.

Fuel level warning lamp lights up orange – Fuel level has reached the reserve mark. Display switched to TRIP F.

FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emissionor safety-critical fault.

Battery warning lamp lights up red – Voltage in vehicle system too low.

CONTROLS

Combination5.14 instrument - display

When you switch on the ignition, all display segments light up for a second as a function test.

700118-01

LEnGTth

Following the display function test, the wheel circumference LEnGth is shown for one second.

Info

1870 mm corresponds to the circumference of the 17" front wheel with a series production tire.

The display then changes to the last selected mode.

700119-01

CONTROLS		27

Combination5.15	instrument - speedometer
		The speed is shown in kilometers per hour km/h or in miles per hour Mph.

700114-01

Setting5.16 kilometers or miles

Info

If you change the unit, the value ODO is retained and converted accordingly.

Making the setting according to the country.

Condition

The motorcycle is standing.

CONTROLS

–Switch on the ignition by turning the ignition key to the position .

–Press the MODE button repeatedly until the ODO 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

700120-01

Combination5.17 instrument - time

The time is shown in area of the display.

Info

The time has to be reset after the battery is reconnected or when the fuse is changed.

700115-01

Setting5.18 the clock

Condition

The motorcycle is standing.

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