KTM 690 Duke 2016 Owner's manual

Category
Motorcycles
Type
Owner's manual
OWNER'S MANUAL 2016
690 Duke
Art. no. 3213398en
DEAR KTM CUSTOMER 1
*3213398en*
3213398en
02/2016
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 properly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 26) Dealer's stamp
Engine number ( p. 28)
Key number ( p. 27)
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to develop-
ments in design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle GmbH 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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
DEAR KTM CUSTOMER 2
Reproduction, even in part, as well as copying of all kinds, 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: TÃœV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
690 Duke US (F9775P3, F9775P4)
TABLE OF CONTENTS 3
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
1.1 Symbols used ...................................................... 7
1.2 Formats used....................................................... 8
2 SAFETY ADVICE.............................................................. 9
2.1 Use definition - intended use ................................ 9
2.2 Safety advice....................................................... 9
2.3 Degrees of risk and symbols................................ 10
2.4 Overview of labels .............................................. 12
2.5 Reporting safety defects ..................................... 15
2.6 Noise emission warranty ..................................... 16
2.7 Operating noise warning ..................................... 16
2.8 Consumer rights................................................. 16
2.9 Tampering warning............................................. 17
2.10 Safe operation ................................................... 17
2.11 Protective clothing ............................................. 18
2.12 Work rules......................................................... 18
2.13 Environment...................................................... 19
2.14 Owner's Manual ................................................. 19
3 IMPORTANT NOTES...................................................... 20
3.1 Manufacturer and implied warranty...................... 20
3.2 Operating and auxiliary substances ...................... 20
3.3 Spare parts, accessories ..................................... 20
3.4 Service ............................................................. 21
3.5 Figures ............................................................. 21
3.6 Customer service................................................ 21
4 VIEW OF VEHICLE ........................................................ 22
4.1 View of vehicle, front left side ............................. 22
4.2 View of vehicle, rear right side............................. 24
5 SERIAL NUMBERS ....................................................... 26
5.1 Chassis number ................................................. 26
5.2 Type label ......................................................... 26
5.3 Key number....................................................... 27
5.4 Engine number .................................................. 28
5.5 Fork part number ............................................... 28
5.6 Shock absorber article number ............................ 29
6 CONTROLS................................................................... 30
6.1 Clutch lever....................................................... 30
6.2 Hand brake lever................................................ 30
6.3 Throttle grip ...................................................... 31
6.4 Switches on the left side of the handlebar ............ 31
6.4.1 Combination switch........................................ 31
6.4.2 Light switch .................................................. 32
6.4.3 Menu switch.................................................. 32
6.4.4 Turn signal switch.......................................... 33
6.4.5 Horn button .................................................. 33
6.5 Switches on the right side of the handlebar .......... 34
6.5.1 Emergency OFF switch ................................... 34
6.5.2 Electric starter button .................................... 34
6.5.3 Ignition/steering lock...................................... 35
6.6 Opening the filler cap......................................... 35
6.7 Closing the filler cap .......................................... 36
6.8 Seat lock........................................................... 37
6.9 Tool set............................................................. 37
6.10 Handrails .......................................................... 38
6.11 Passenger footrest.............................................. 38
6.12 Shift lever ......................................................... 39
6.13 Foot brake lever ................................................. 40
TABLE OF CONTENTS 4
6.14 Side stand......................................................... 40
7 COMBINATION INSTRUMENT ....................................... 41
7.1 Overview ........................................................... 41
7.2 Indicator lamps.................................................. 42
7.3 Speed............................................................... 43
7.4 Time................................................................. 44
7.5 Temperature...................................................... 44
7.6 Gear display ...................................................... 45
7.7 Fuel tank capacity.............................................. 45
7.8 Coolant temperature indicator ............................. 46
7.9 "Favorites"......................................................... 46
7.10 "Trip 1" ............................................................. 47
7.11 "Trip 2" ............................................................. 47
7.12 "General info" .................................................... 48
7.13 "Set Favorites" ................................................... 48
7.14 "Settings" .......................................................... 49
7.15 "Warning" .......................................................... 49
7.16 "TC/ABS"........................................................... 50
7.17 "MTC/ABS" ........................................................ 50
7.18 "Language" ........................................................ 51
7.19 "Distance" ......................................................... 52
7.20 "Temp".............................................................. 52
7.21 "Pressure" ......................................................... 53
7.22 "Volume" ........................................................... 53
7.23 Set the time and date......................................... 54
7.24 "Shift Light" ...................................................... 55
7.25 "Extra functions" ................................................ 55
7.26 Drive Mode (optional) ......................................... 56
8 PREPARING FOR USE................................................... 57
8.1 Advice on first use ............................................. 57
8.2 Running in the engine ........................................ 58
8.3 Loading the vehicle............................................ 59
9 RIDING INSTRUCTIONS................................................ 61
9.1 Performing checks and vehicle care when
preparing for use................................................ 61
9.2 Starting............................................................. 62
9.3 Starting off........................................................ 63
9.4 Shifting, riding .................................................. 63
9.5 Engine braking control (MSR) .............................. 67
9.6 Applying the brakes............................................ 67
9.7 Stopping, parking............................................... 69
9.8 Transport .......................................................... 70
9.9 Refueling .......................................................... 71
10 SERVICE SCHEDULE .................................................... 73
10.1 Additional information........................................ 73
10.2 Required work ................................................... 73
10.3 Recommended work ........................................... 75
11 TUNING THE CHASSIS ................................................. 76
11.1 Adjusting the spring preload of the shock
absorber ........................................................ 76
11.2 Adjusting the footrests........................................ 76
12 SERVICE WORK ON THE CHASSIS................................. 79
12.1 Raising the motorcycle with the rear lifting gear.... 79
12.2 Removing the rear of the motorcycle from the
lifting gear ........................................................ 79
12.3 Lifting the motorcycle with the front lifting gear.... 80
12.4 Taking the motorcycle from the front lifting gear ... 81
12.5 Removing the passenger seat .............................. 82
TABLE OF CONTENTS 5
12.6 Mounting the passenger seat............................... 82
12.7 Checking the chain for dirt.................................. 83
12.8 Cleaning the chain ............................................. 83
12.9 Checking the chain tension ................................. 84
12.10 Adjusting the chain tension................................. 86
12.11 Checking the chain, rear sprocket, and engine
sprocket............................................................ 88
12.12 Adjusting the basic position of the clutch lever ..... 90
12.13 Checking/correcting the fluid level of the
hydraulic clutch................................................. 91
13 BRAKE SYSTEM ........................................................... 93
13.1 Antilock braking system (ABS) ............................ 93
13.2 Adjusting the basic position of the hand brake
lever ................................................................. 94
13.3 Checking the brake discs .................................... 95
13.4 Checking the brake fluid level of the front brake ... 96
13.5 Adding front brake fluid .................................. 97
13.6 Checking the front brake linings .......................... 98
13.7 Checking the free travel of foot brake lever ........... 99
13.8 Adjusting the basic position of the foot brake
lever ............................................................ 100
13.9 Checking rear brake fluid level .......................... 101
13.10 Adding rear brake fluid ................................. 102
13.11 Checking the rear brake linings ......................... 104
14 WHEELS, TIRES ......................................................... 105
14.1 Removing the front wheel .............................. 105
14.2 Installing the front wheel .............................. 106
14.3 Removing the rear wheel ............................... 108
14.4 Installing the rear wheel ................................ 110
14.5 Checking the rear hub rubber dampers ........... 113
14.6 Checking the tire condition ............................... 114
14.7 Checking the tire pressure ................................ 116
15 ELECTRICAL SYSTEM ................................................. 117
15.1 Removing the battery .................................... 117
15.2 Installing the battery ..................................... 119
15.3 Recharging the battery .................................. 120
15.4 Changing the main fuse.................................... 123
15.5 Changing the ABS fuses ................................... 125
15.6 Changing the fuses of individual power
consumers....................................................... 126
15.7 Removing the headlight mask with the
headlight......................................................... 129
15.8 Installing the headlight mask with the
headlight......................................................... 130
15.9 Changing the headlight bulb ............................. 131
15.10 Changing the parking light bulb......................... 133
15.11 Changing the turn signal bulb ........................... 134
15.12 Checking the headlight setting .......................... 135
15.13 Adjusting the headlight range............................ 135
15.14 Diagnostics connector ...................................... 136
16 COOLING SYSTEM ...................................................... 137
16.1 Cooling system ................................................ 137
16.2 Checking the antifreeze and coolant level........... 137
16.3 Checking the coolant level in the compensating
tank................................................................ 139
16.4 Draining the coolant ..................................... 141
16.5 Filling/bleeding the cooling system ................. 142
17 TUNING THE ENGINE................................................. 144
17.1 Checking the basic position of the shift lever ...... 144
TABLE OF CONTENTS 6
17.2 Adjusting the basic position of the shift
lever ............................................................ 144
17.3 Drive Mode (optional) ....................................... 145
17.4 Motorcycle traction control (optional) (MTC) ....... 146
18 SERVICE WORK ON THE ENGINE ................................ 147
18.1 Checking the engine oil level............................. 147
18.2 Changing the engine oil and oil filter, cleaning
the oil screens ............................................. 147
18.3 Adding engine oil............................................. 152
19 CLEANING, CARE ....................................................... 154
19.1 Cleaning the motorcycle ................................... 154
19.2 Checks and maintenance steps for winter
operation......................................................... 156
20 STORAGE................................................................... 157
20.1 Storage ........................................................... 157
20.2 Preparing for use after storage........................... 158
21 TROUBLESHOOTING .................................................. 159
22 TECHNICAL DATA....................................................... 162
22.1 Engine............................................................ 162
22.2 Engine tightening torques ................................. 163
22.3 Capacities ....................................................... 167
22.3.1 Engine oil ................................................... 167
22.3.2 Coolant....................................................... 167
22.3.3 Fuel ........................................................... 167
22.4 Chassis ........................................................... 168
22.5 Electrical system.............................................. 169
22.6 Tires............................................................... 170
22.7 Fork................................................................ 170
22.8 Shock absorber................................................ 170
22.9 Chassis tightening torques ................................ 171
23 SUBSTANCES ............................................................ 175
24 AUXILIARY SUBSTANCES ........................................... 178
25 STANDARDS .............................................................. 180
26 INDEX OF SPECIAL TERMS ......................................... 181
27 LIST OF ABBREVIATIONS............................................ 182
28 LIST OF SYMBOLS...................................................... 183
28.1 Red symbols.................................................... 183
28.2 Yellow and orange symbols................................ 183
28.3 Green and blue symbols.................................... 183
INDEX ............................................................................... 185
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).
Indicates information with more details or tips.
Indicates the result of a testing step.
1 MEANS OF REPRESENTATION 8
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brandâ„¢ Identifies a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the
glossary.
2 SAFETY ADVICE 9
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 instruc-
tions 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 10
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
11
2 SAFETY ADVICE 12
2.4 Overview of labels
V00182-10
2 SAFETY ADVICE 13
1 Type label, Canada
2 Information, chain tension
3 Information, emission control
4 Information, putting into operation
5 Information, noise emission
6 Type label, USA
K00423-01
Type label, Canada
700207-01
Information, chain tension
2 SAFETY ADVICE 14
K00424-01
Information, emission control
700210-01
Information, putting into operation
2 SAFETY ADVICE 15
K00426-01
Information, noise emission
K00425-01
Type label, USA
2.5 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 multiple 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 remedy campaign. However, NHTSA cannot become involved in individual problems between you, your
dealer, or KTM North America, Inc.
2 SAFETY ADVICE 16
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 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.
2.6 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
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
2.7 Operating noise warning
This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use.
Otherwise, the owner may become subject to penalties under the applicable ordinances.
2.8 Consumer rights
Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Different rights may apply, according to national or regional legislation.
2 SAFETY ADVICE 17
2.9 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 pur-
chaser 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:
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.
2.10 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.
2 SAFETY ADVICE 18
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.
2.11 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.
2.12 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe-
ses. 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.
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120
  • Page 121 121
  • Page 122 122
  • Page 123 123
  • Page 124 124
  • Page 125 125
  • Page 126 126
  • Page 127 127
  • Page 128 128
  • Page 129 129
  • Page 130 130
  • Page 131 131
  • Page 132 132
  • Page 133 133
  • Page 134 134
  • Page 135 135
  • Page 136 136
  • Page 137 137
  • Page 138 138
  • Page 139 139
  • Page 140 140
  • Page 141 141
  • Page 142 142
  • Page 143 143
  • Page 144 144
  • Page 145 145
  • Page 146 146
  • Page 147 147
  • Page 148 148
  • Page 149 149
  • Page 150 150
  • Page 151 151
  • Page 152 152
  • Page 153 153
  • Page 154 154
  • Page 155 155
  • Page 156 156
  • Page 157 157
  • Page 158 158
  • Page 159 159
  • Page 160 160
  • Page 161 161
  • Page 162 162
  • Page 163 163
  • Page 164 164
  • Page 165 165
  • Page 166 166
  • Page 167 167
  • Page 168 168
  • Page 169 169
  • Page 170 170
  • Page 171 171
  • Page 172 172
  • Page 173 173
  • Page 174 174
  • Page 175 175
  • Page 176 176
  • Page 177 177
  • Page 178 178
  • Page 179 179
  • Page 180 180
  • Page 181 181
  • Page 182 182
  • Page 183 183
  • Page 184 184
  • Page 185 185
  • Page 186 186
  • Page 187 187
  • Page 188 188
  • Page 189 189
  • Page 190 190
  • Page 191 191
  • Page 192 192

KTM 690 Duke 2016 Owner's manual

Category
Motorcycles
Type
Owner's manual

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI