KTM 690 SUPERMOTO, 690 SUPERMOTO R Manual

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OWNER'S MANUAL 2008

690bSUPERMOTO

690bSUPERMOTObR

ART. NO. 3211244en

DEAR KTM 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 great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number/type label ( P. 16)

Dealer's stamp

Engine number ( P. 17)

Key number ( P. 16)

The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small deviations arising from further development in design and construction.

All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop prudction of a particular model without prior notice. KTM accepts no liability for delivery options, deviations 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

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

MEANS OF REPRESENTATION ...............................................	6
IMPORTANT NOTES...............................................................	7
VIEW OF VEHICLE................................................................	12
View of vehicle, front left side............................................	12
View of vehicle, rear right side ...........................................	14
LOCATION OF SERIAL NUMBERS .........................................	16
Chassis number/type label.................................................	16
Key number .....................................................................	16
Engine number.................................................................	17
Fork part number..............................................................	17
Shock absorber part number..............................................	18
OPERATING ELEMENTS.......................................................	19
Clutch lever .....................................................................	19
Hand brake lever ..............................................................	20
Light switch .....................................................................	20
Headlight flasher switch....................................................	21
Flasher switch..................................................................	21
Horn ...............................................................................	22
Ignition/steering lock ........................................................	22
Emergency OFF switch......................................................	23
Electric starter button .......................................................	23
Combination instrument....................................................	24
Combination instrument - function buttons .........................	24
Combination instrument - tachometer.................................	25
Combination instrument - control lamps .............................	25
Combination instrument - Display ......................................	26
Combination instrument - speed display .............................	27
Setting kilometers or miles ................................................	27
Combination instrument - time ..........................................	28

Setting the clock ..............................................................	28
Combination instrument -bODO display ...............................	29
Combination instrument - setting/resettingbTRIPb1 display....	29
Combination instrument - setting/resettingbTRIPb2 display....	30
Combination instrument -bTRIPbF 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
GREASING AND SERVICE TABLE ..........................................	53
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................	53
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)...................	55
MAINTENANCE WORK ON CHASSIS AND ENGINE.................	56
Jacking up front of motorcycle ...........................................	56
Taking front from work stand .............................................	56
Jacking up rear of motorcycle ............................................	57
Take the rear from the work stand. .....................................	57
Fork/shock absorber..........................................................	58
Adjusting compression damping of fork
(690bSUPERMOTObR).......................................................	58
Adjusting rebound damping of fork.....................................	59
Compression damping of shock absorber
(690bSUPERMOTObR).......................................................	60
Adjusting the low-speed compression damping of the shock
absorber (690bSUPERMOTObR) .........................................	60
Adjusting high-speed compression damping of the shock
absorber (690bSUPERMOTObR) .........................................	61
Adjusting rebound damping of the shock absorber ...............	62
Bleeding fork legs.............................................................	63
Checking chain dirt ..........................................................	64
Cleaning the chain............................................................	64
Checking the chain tension ...............................................	65
Adjusting chain tension.....................................................	66
Checking rear sprocket / engine sprocket for wear ................	68
Checking chain wear.........................................................	69
Checking brake discs ........................................................	70

Adjusting basic position of handbrake lever.........................	71
Checking front brake fluid level..........................................	71
Topping up the front brake fluidbx....................................	72
Brake linings....................................................................	75
Checking the front brake linings.........................................	75
Checking free play of foot brake lever .................................	76
Checking rear brake fluid level...........................................	77
Topping up brake fluid of front brakebx.............................	77
Checking rear brake linings ...............................................	79
Removing front wheelbx ..................................................	80
Fitting front wheelbx.......................................................	81
Removing rear wheelbx....................................................	82
Fitting rear wheelbx ........................................................	83
Checking the rear hub rubber dampersbx..........................	85
Tire condition checking.....................................................	86
Checking tire air pressure..................................................	87
Checking spoke tension (690bSUPERMOTO) .......................	88
Removing the seat ............................................................	89
Mounting the seat ............................................................	89
Reinstalling the fuel tank ..................................................	90
Positioning the fuel tank ...................................................	91
Removing the batterybx...................................................	92
Installing the batterybx....................................................	93
Recharging the batterybx.................................................	93
Changing the main fuse ....................................................	95
Changing fuses of individual power consumers ....................	97
Removing headlight mask with headlight ............................	99
Refitting the headlight mask with the headlight.................	100
Changing headlight bulb .................................................	101

CONTENTS

Changing the parking lamp..............................................	102
Changing flasher bulb .....................................................	103
Checking headlamp setting..............................................	104
Adjusting the headlight range ..........................................	105
Cooling system ...............................................................	106
Checking antifreeze and coolant level ...............................	106
Checking the coolant level...............................................	109
Draining coolantbx........................................................	110
Filling/bleeding the cooling systembx..............................	111
Adjusting basic position of clutch lever.............................	113
Checking/correcting fluid level of hydraulic clutch .............	114
Checking play in gas Bowden cable ..................................	115
Adjusting play in gas Bowden cablebx.............................	116
Adjusting the handlebar anglebx.....................................	117
Checking engine oil level.................................................	117
Changing engine oil and oil filter, cleaning oil
screensbx.....................................................................	118
Draining engine oilbx ....................................................	118
Removing the oil filterbx................................................	120
Mounting oil filterbx......................................................	121
Cleaning oil screensbx...................................................	121
Filling up with engine oilbx............................................	123
Topping up engine oil .....................................................	124
TROUBLESHOOTING..........................................................	126
FLASHING CODE ...............................................................	129
CLEANING.........................................................................	132
Cleaning motorcycle .......................................................	132
CONSERVATION FOR WINTER OPERATION .........................	134
Conservation for winter operation .....................................	134

STORAGE ..........................................................................	135
Storage..........................................................................	135
Putting into operation after storage ..................................	136
TECHNICAL DATA - ENGINE...............................................	137
Capacity - engine oil .......................................................	138
Capacity - coolant...........................................................	138
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...........	139
TECHNICAL DATA - CHASSIS .............................................	142
Lighting equipment ........................................................	143
Capacity - fuel................................................................	144
TECHNICAL DATA - FORK...................................................	145
TECHNICAL DATA - SHOCK ABSORBER ..............................	146
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES .........	148
SUBSTANCES....................................................................	152
AUXILIARY SUBSTANCES...................................................	155
STANDARDS......................................................................	157
INDEX ...............................................................................	158

MEANS OF REPRESENTATION

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

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad.

Info

The motorcycle is authorized for public road traffic in the homologous version only.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT NOTES

Spare parts, accessories

For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

For the latestbKTMbPowerParts for your vehicle, see

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

Transport

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

Do not place the vehicle where there are flammable or explosive substances.

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.

IMPORTANT NOTES

Warning notes

In your own interest, read the specified warning notes.

Info

Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Caution

Danger that could possibly lead to slight injuries.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

Read 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

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

	View of vehicle, front left side

100187-10

VIEW OF VEHICLE

1Combination instrument

2Rear mirror

3Clutch lever

4Seat

5Handrail

6Front brake caliper

7Left fuel tap

8Shift lever

9Engine number

10	Side stand

KTM 690 SUPERMOTO, 690 SUPERMOTO R Manual

	VIEW OF VEHICLE	14

	View of vehicle, rear right side

100188-10

	VIEW OF VEHICLE		15

1		Seat lock

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

3		Filler cap

4		Emergency OFF switch, electric starter button

5		Hand brake lever

6		Chassis number, type label

7		Rear brake caliper

8		Passenger footrests

9		Foot brake pedal

10		Engine oil level viewer

11		Right fuel tap

LOCATION OF SERIAL NUMBERS

Chassis number/type label

The chassis numberb is stamped on the steering head on the right.

The type labelb is located under the chassis number.

500006-01

Key number

The key numberb can be found on the istbKEYCODECARD.

You need the key number to order a spare key. Keep thebKEYCODECARD in a safe place.

100179-10

LOCATION OF SERIAL NUMBERS

Engine number

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

500001-01

Fork part number

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

100184-10

LOCATION OF SERIAL NUMBERS

Shock absorber part number

The shock absorber part numberb is stamped on the top of the shock absorber above the adjusting ring on the engine side.

100185-10

OPERATING ELEMENTS

Clutch lever

(690bSUPERMOTO)

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

100113-10

(690bSUPERMOTObR)

The clutch leverb is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

100114-10

OPERATING ELEMENTS

Hand brake lever

The hand brake leverb is located on the right side of the handlebar and operates the front wheel brake.

The hand brake lever operates the front brake.

500018-01

Light switch

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

Possible states

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

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

500020-01

OPERATING ELEMENTS

Headlight flasher switch

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

Possible states

•Headlight flasher switch in neutral position

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

500020-11

Flasher switch

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

Possible states

Flasher light off

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

Flasher light, right, on bFlasher 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.

500021-10

OPERATING ELEMENTS

Horn

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

Possible states

•Horn buttonb in neutral position

•Horn buttonb pressed bThe horn is operated in this position.

500021-11

Ignition/steering lock

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

Possible states

Ignition off bIn 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 bIn this position, the ignition circuit is closed, and the engine can be started.

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

500019-01

OPERATING ELEMENTS

Emergency OFF switch

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

Possible states

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

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

500022-10

Electric starter button

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

Possible states

•Electric starter buttonb in basic position

•Electric starter buttonb pressed bIn this position, the electric starter is actuated.

500022-11

OPERATING ELEMENTS

Combination instrument

The combination instrument is attached in fromt of the handlebar. The combination instrument is divided into 4 function areas.bFunction buttons

TachometerIndicator lightsDisplay

700116-01

Combination instrument - function buttons

Press thebMODEbbuttonb to change the display mode.

Possible display modes are total distance covered (ODO), tripmasterb1b(TRIPb1) and tripmasterb2b(TRIPb2).

Press thebSETbbuttonb to reset tripmasterb1b(TRIPb1) and tripmasterb2b(TRIPb2) tob0.0. Buttonb has no function.

700117-01

OPERATING ELEMENTS

Combination instrument - tachometer

The tachometerb displays the engine speed in revolutions per minute.

The red markingb shows the excess engine speed range.

100118-10

Combination instrument - control lamps

The indicator lamps provide additional information on the operating state of the motorcycle.

	Possible states
		Flashing indicator flashes green in flash rhythm bFlasher light is switched
		on.
		Idling speed indicator lamp lights up green bTransmission is in neutral.
		High beam indicator lamp lights up blue bHigh beam is switched on.
100119-10		Temperature warning lamp lights up red bCoolant has reached a critical
		value.
		value.
		Fuel level warning lamp lights up orange bFuel level has reached the reserve
		mark. Display switches tobTRIPbF.
		FIbwarning lamp (MIL) lights/flashes orange bThe OBD has detected an

		emissionor safety-critical error.
		emissionor safety-critical error.

OPERATING ELEMENTS	26
		Battery warning lamp lights up bVoltage in electrical system too low.

Combination 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 circumferencebLEnGth 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

OPERATING ELEMENTS

Combination instrument - speed display

The speedb is displayed in kilometers per hourbkm/h or miles per hourbMph.

700114-01

Setting kilometers or miles

Info

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

Making the setting according to the country.

Condition

The motorcycle is standing.

OPERATING ELEMENTS

Turn the ignition key to the positionb.

Press thebMODEbbutton several times until thebODO display mode is active.

Keep the MODEbbutton pressed until the display mode changes frombKm/h to Mph or from Mph to Km/h.

Specification

Activation duration of MODEbbutton	10bs

700120-01

Combination instrument - time

The time is shown in areab of the display.

Info

The time must be adjusted after the battery is disconnected or the fuse is changed.

700115-01

Setting the clock

Condition

The motorcycle is standing.

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