KTM 690 Duke 2014 Owners manual
OWNER'S MANUAL 2014
690 Duke EU
690 Duke AUS/UK
690 Duke R EU
690 Duke R AUS/UK
690 Duke R MAL
Art. no. 3213103en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
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 a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.
Chassis number ( p. 20) Dealer's stamp
Engine number ( p. 22)
Key number ( p. 21)
The owner's manual contained the latest information for this model series 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 belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER 2
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
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
1.1 Symbols used ...................................................... 7
1.2 Formats used....................................................... 7
2 SAFETY ADVICE.............................................................. 8
2.1 Use definition - intended use ................................ 8
2.2 Safety advice ....................................................... 8
2.3 Degrees of risk and symbols.................................. 9
2.4 Tampering warning............................................... 9
2.5 Safe operation ................................................... 10
2.6 Protective clothing ............................................. 11
2.7 Work rules ......................................................... 11
2.8 Environment...................................................... 11
2.9 Owner's Manual ................................................. 12
3 IMPORTANT INFORMATION .......................................... 13
3.1 Guarantee, warranty ........................................... 13
3.2 Operating and auxiliary substances ...................... 13
3.3 Spare parts, accessories ..................................... 13
3.4 Service ............................................................. 13
3.5 Figures ............................................................. 14
3.6 Customer service................................................ 14
4 VIEW OF VEHICLE ........................................................ 16
4.1 View of vehicle, front left side (example) .............. 16
4.2 View of vehicle, rear right side (example).............. 18
5 SERIAL NUMBERS ....................................................... 20
5.1 Chassis number ................................................. 20
5.2 Type label ......................................................... 20
5.3 Key number....................................................... 21
5.4 Engine number .................................................. 22
5.5 Fork part number ............................................... 23
5.6 Shock absorber part number ............................... 23
6 CONTROLS................................................................... 25
6.1 Clutch lever ....................................................... 25
6.2 Hand brake lever................................................ 25
6.3 Throttle grip ...................................................... 26
6.4 Horn button....................................................... 27
6.5 Light switch ...................................................... 27
6.6 Headlight flasher switch ..................................... 28
6.7 Turn signal switch.............................................. 28
6.8 Emergency OFF switch ....................................... 29
6.9 Electric starter button......................................... 29
6.10 Ignition/steering lock.......................................... 30
6.11 Combination instrument ..................................... 30
6.11.1 Overview ....................................................... 30
6.11.2 function buttons ............................................ 31
6.11.3 Tachometer................................................... 31
6.11.4 Combination instrument - indicator lamps........ 32
6.11.5 Display ......................................................... 33
6.11.6 Speed display................................................ 34
6.11.7 Setting kilometers or miles ............................. 34
6.11.8 Time............................................................. 35
6.11.9 Setting the clock ........................................... 35
6.11.10 ODO display .................................................. 36
6.11.11 Setting/resetting display TRIP 1 ...................... 36
6.11.12 Setting/resetting display TRIP 2 ...................... 37
6.11.13 TRIP F display............................................... 38
6.11.14 GEAr display ................................................. 38
6.11.15 Coolant temperature indicator ......................... 39
6.12 Opening the filler cap......................................... 39
TABLE OF CONTENTS 4
6.13 Closing the filler cap .......................................... 40
6.14 Seat lock........................................................... 41
6.15 Tool set............................................................. 41
6.16 Handrails .......................................................... 42
6.17 Passenger footrests ............................................ 42
6.18 Shift lever ......................................................... 43
6.19 Foot brake lever ................................................. 45
6.20 Side stand......................................................... 46
7 PREPARING FOR USE................................................... 47
7.1 Advice on first use ............................................. 47
7.2 Running in the engine ........................................ 48
7.3 Loading the vehicle............................................ 49
8 RIDING INSTRUCTIONS................................................ 51
8.1 Performing checks and vehicle care when
preparing for use................................................ 51
8.2 Starting............................................................. 52
8.3 Starting off........................................................ 54
8.4 Shifting, riding .................................................. 54
8.5 Applying the brakes............................................ 58
8.6 Stopping, parking............................................... 60
8.7 Transport .......................................................... 61
8.8 Refueling .......................................................... 62
9 SERVICE SCHEDULE .................................................... 64
9.1 Service schedule................................................ 64
10 TUNING THE CHASSIS ................................................. 66
10.1 Fork/shock absorber (Duke R).............................. 66
10.2 Adjusting the compression damping of the fork
(Duke R) ........................................................... 66
10.3 Adjusting the rebound damping of the fork
(Duke R) ........................................................... 67
10.4 Compression damping of the shock absorber......... 68
10.5 Adjusting the high-speed compression damping
of the shock absorber (Duke R) ........................... 68
10.6 Adjusting the low-speed compression damping of
the shock absorber (Duke R) ............................... 69
10.7 Adjusting the rebound damping of the shock
absorber (Duke R) .............................................. 70
10.8 Adjusting the spring preload of the shock
absorber x....................................................... 71
10.9 Adjusting the footrests........................................ 73
10.10 Adjusting the foot brake lever stub (Duke R) ......... 76
11 SERVICE WORK ON THE CHASSIS................................. 77
11.1 Raising the motorcycle with the rear wheel
stand ................................................................ 77
11.2 Taking the motorcycle off of the rear wheel
stand ................................................................ 77
11.3 Raising the motorcycle with the front wheel
stand ................................................................ 78
11.4 Taking the motorcycle off of the front wheel
stand ................................................................ 79
11.5 Removing the passenger seat .............................. 79
11.6 Mounting the passenger seat............................... 80
11.7 Removing the passenger seat cover (Duke R) ........ 80
11.8 Mounting the passenger seat cover (Duke R)......... 81
11.9 Checking the chain for dirt.................................. 81
11.10 Cleaning the chain ............................................. 82
11.11 Checking the chain tension ................................. 83
11.12 Adjusting the chain tension................................. 85
11.13 Checking the chain, rear sprocket and engine
sprocket............................................................ 87
TABLE OF CONTENTS 5
11.14 Adjusting the basic position of the clutch lever ..... 89
11.15 Checking/rectifying the fluid level of the
hydraulic clutch................................................. 90
12 BRAKE SYSTEM ........................................................... 91
12.1 ABS/antilock brake system.................................. 91
12.2 Adjusting the basic position of the hand brake
lever ................................................................. 92
12.3 Checking the brake discs .................................... 93
12.4 Checking the brake fluid level of the front brake ... 94
12.5 Adding front brake fluid x................................. 95
12.6 Checking the front brake linings .......................... 97
12.7 Checking the free travel of foot brake lever ........... 98
12.8 Adjusting the basic position of the foot brake
lever x ............................................................ 99
12.9 Checking rear brake fluid level .......................... 102
12.10 Adding rear brake fluid x................................ 103
12.11 Checking the rear brake linings ......................... 105
13 WHEELS, TIRES ......................................................... 106
13.1 Removing the front wheel x ............................ 106
13.2 Installing the front wheel x............................. 107
13.3 Removing the rear wheel x.............................. 110
13.4 Installing the rear wheel x .............................. 111
13.5 Checking the rear hub rubber dampers x.......... 114
13.6 Checking the tire condition ............................... 115
13.7 Checking the tire pressure ................................ 117
14 ELECTRICAL SYSTEM ................................................. 118
14.1 Removing the battery x .................................. 118
14.2 Installing the battery x ................................... 119
14.3 Recharging the battery x ................................ 120
14.4 Changing the main fuse .................................... 123
14.5 Changing the ABS fuses ................................... 125
14.6 Changing the fuses of individual power
consumers....................................................... 126
14.7 Removing the headlight mask with the
headlight......................................................... 129
14.8 Refitting the headlight mask with the
headlight......................................................... 130
14.9 Changing the headlight bulb ............................. 131
14.10 Changing the parking light bulb......................... 133
14.11 Changing the turn signal bulb (Duke) ................. 134
14.12 Checking the headlight setting .......................... 135
14.13 Adjusting the headlight range............................ 136
15 COOLING SYSTEM ...................................................... 137
15.1 Cooling system ................................................ 137
15.2 Checking the antifreeze and coolant level ........... 137
15.3 Checking the coolant level in the compensating
tank................................................................ 140
15.4 Draining the coolant x.................................... 141
15.5 Filling/bleeding the cooling system x ............... 142
16 TUNING THE ENGINE................................................. 144
16.1 Setting the engine characteristics...................... 144
16.2 Checking the basic position of the shift lever ...... 145
16.3 Adjusting the basic position of the shift
lever x .......................................................... 145
17 SERVICE WORK ON THE ENGINE ................................ 148
17.1 Checking the engine oil level............................. 148
17.2 Changing the engine oil and filter, cleaning the
oil screens x.................................................. 148
17.3 Adding engine oil............................................. 153
TABLE OF CONTENTS 6
18 CLEANING, CARE ....................................................... 154
18.1 Cleaning the motorcycle ................................... 154
18.2 Checks and maintenance steps for winter
operation......................................................... 156
19 STORAGE................................................................... 157
19.1 Storage ........................................................... 157
19.2 Preparing for use after storage........................... 158
20 TROUBLESHOOTING .................................................. 159
21 BLINK CODE .............................................................. 162
22 TECHNICAL DATA....................................................... 169
22.1 Engine............................................................ 169
22.2 Engine tightening torques................................. 170
22.3 Capacities ....................................................... 173
22.3.1 Engine oil ................................................... 173
22.3.2 Coolant....................................................... 174
22.3.3 Fuel ........................................................... 174
22.4 Chassis ........................................................... 174
22.5 Electrical system.............................................. 176
22.6 Tires............................................................... 177
22.7 Fork................................................................ 177
22.7.1 Duke .......................................................... 177
22.7.2 Duke R ....................................................... 177
22.8 Shock absorber ................................................ 178
22.8.1 Duke .......................................................... 178
22.8.2 Duke R ....................................................... 179
22.9 Chassis tightening torques ................................ 180
23 SUBSTANCES ............................................................ 185
24 AUXILIARY SUBSTANCES ........................................... 189
25 STANDARDS .............................................................. 191
INDEX ............................................................................... 192
1 MEANS OF REPRESENTATION 7
1.1 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 performed by an authorized KTM workshop. There, your motorcycle will be optimally
cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
2 SAFETY ADVICE 8
2.1 Use definition - intended use
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 only authorized for operation on public roads in the homologated version.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2 SAFETY ADVICE 9
2.3 Degrees of risk and symbols
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 may lead to minor injuries 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.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the 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 purchaser or while it is in use, or
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:
2 SAFETY ADVICE 10
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufac-
turer.
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE 11
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 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 parentheses. E.g.: bearing puller (15112017000)
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.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle
sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE 12
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the
vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT INFORMATION 13
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered
for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are 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 or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to
advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis
is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage
and breakage of components.
3 IMPORTANT INFORMATION 14
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear of
components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace
parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
15
4 VIEW OF VEHICLE 16
4.1 View of vehicle, front left side (example)
C00298-10
4 VIEW OF VEHICLE 17
1 Clutch lever ( p. 25)
2 Seat
3 Passenger seat
4 Handrails ( p. 42)
5 Seat lock ( p. 41)
6 Engine number ( p. 22)
7 Shift lever ( p. 43)
8 Side stand ( p. 46)
4 VIEW OF VEHICLE 18
4.2 View of vehicle, rear right side (example)
101969-10
4 VIEW OF VEHICLE 19
1 Tool set ( p. 41)
1 Map‑Select switch
2 Light switch ( p. 27)
2 Headlight flasher switch ( p. 28)
2 Turn signal switch ( p. 28)
2 Horn button ( p. 27)
3 Filler cap
4 Ignition/steering lock ( p. 30)
5 Emergency OFF switch ( p. 29)
5 Electric starter button ( p. 29)
6 Hand brake lever ( p. 25)
7 Chassis number ( p. 20)
8 Fuse box
9 Type label ( p. 20)
10 Passenger footrests ( p. 42)
11 Foot brake lever ( p. 45)
12 Level viewer, engine oil
5 SERIAL NUMBERS 20
5.1 Chassis number
The chassis number1is stamped on the right side of the steering head.
602542-10
5.2 Type label
The type label1is located on the right side of the frame.
C00301-10
5 SERIAL NUMBERS 21
(690 Duke AUS/UK, 690 Duke R AUS/UK)
The type label1is located on the left side of the frame.
101970-10
5.3 Key number
The key number1can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
B00755-10
5 SERIAL NUMBERS 22
5.4 Engine number
(Duke)
The engine number1is located on the left side of the engine under the engine
sprocket.
C00302-10
(Duke R)
The engine number1is located on the left side of the engine under the engine
sprocket.
602550-10
5 SERIAL NUMBERS 23
5.5 Fork part number
The fork part number1is stamped on the inner side of the fork stub.
C00303-10
5.6 Shock absorber part number
(Duke)
The shock absorber part number1is on the left side of the shock absorber.
C00304-10
5 SERIAL NUMBERS 24
(Duke R)
The shock absorber part number1is found on the damper at the rear.
602551-10
6 CONTROLS 25
6.1 Clutch lever
The clutch lever1is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
101963-10
6.2 Hand brake lever
(Duke)
The hand brake lever1is fitted on the right side of the handlebar.
602570-10
6 CONTROLS 26
(Duke R)
The hand brake lever1is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
602552-10
6.3 Throttle grip
The throttle grip1is fitted on the right side of the handlebar.
B00922-10
6 CONTROLS 27
6.4 Horn button
The horn button1is 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.
C00308-11
6.5 Light switch
The light switch1is 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.
C00307-10
6 CONTROLS 28
6.6 Headlight flasher switch
The headlight flasher switch1is 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.
C00307-11
6.7 Turn signal switch
The turn signal switch1is fitted on the left side of the handlebar.
Possible states
Turn signal off
Left turn signal on – The turn signal switch is pressed to the left. The turn
signal switch automatically returns to the central position after use.
Right turn signal on – The turn signal switch is pressed to the right. The
turn signal switch automatically returns to the central position after use.
C00308-10
To switch off the turn signal, press the turn signal switch towards the switch housing.
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