KTM 690 Duke 2018 Owner's manual

Category
Motorcycles
Type
Owner's manual
OWNER'S MANUAL 2018
690 Duke
Art. no. 3213747en
DEAR KTM CUSTOMER
*3213747en*
3213747en
08/2017
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 ride!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 24) Dealer's stamp
Engine number ( p. 25)
Key number ( p. 25)
The Owner's Manual contained the latest information for this model series at the time of going to print. However,
minor differences due to further developments 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, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2017 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 assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÃœV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
690 Duke EU (F9703R4)
TABLE OF CONTENTS
3
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ...................... 8
1.1 Symbols used .................................... 8
1.2 Formats used..................................... 9
2 SAFETY ADVICE.......................................... 10
2.1 Use definition – intended use............ 10
2.2 Misuse............................................ 10
2.3 Safety advice................................... 10
2.4 Degrees of risk and symbols.............. 11
2.5 Tampering warning........................... 12
2.6 Safe operation ................................. 12
2.7 Protective clothing ........................... 13
2.8 Work rules....................................... 14
2.9 Environment.................................... 14
2.10 Owner's Manual ............................... 15
3 IMPORTANT NOTES.................................... 16
3.1 Manufacturer and implied warranty.... 16
3.2 Operating and auxiliary substances .... 16
3.3 Spare parts, accessories ................... 16
3.4 Service ........................................... 17
3.5 Figures ........................................... 17
3.6 Customer service.............................. 17
4 VIEW OF VEHICLE ...................................... 20
4.1 View of vehicle, front left (example) ... 20
4.2 View of vehicle, rear right
(example)........................................ 22
5 SERIAL NUMBERS ..................................... 24
5.1 Chassis number ............................... 24
5.2 Type label ....................................... 24
5.3 Key number..................................... 25
5.4 Engine number ................................ 25
5.5 Fork part number ............................. 26
5.6 Shock absorber article number .......... 26
6 CONTROLS................................................. 27
6.1 Clutch lever..................................... 27
6.2 Hand brake lever.............................. 27
6.3 Throttle grip .................................... 28
6.4 Switches on the left side of the
handlebar........................................ 28
6.4.1 Combination switch...................... 28
6.4.2 Light switch ................................ 29
6.4.3 Menu switch................................ 30
6.4.4 Turn signal switch........................ 30
6.4.5 Horn button ................................ 31
TABLE OF CONTENTS
4
6.5 Switches on the right side of the
handlebar........................................ 32
6.5.1 Emergency OFF switch ................. 32
6.5.2 Electric starter button .................. 32
6.5.3 Ignition/steering lock.................... 33
6.6 Opening the filler cap....................... 34
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
6.14 Side stand....................................... 40
7 COMBINATION INSTRUMENT ..................... 42
7.1 Combination instrument ................... 42
7.2 Indicator lamps................................ 43
7.3 Speed............................................. 45
7.4 Time............................................... 45
7.5 Temperature.................................... 46
7.6 Gear display .................................... 46
7.7 Fuel tank capacity............................ 47
7.8 Coolant temperature indicator ........... 47
7.9 "Favorites"....................................... 48
7.10 "Trip 1" ........................................... 48
7.11 "Trip 2" ........................................... 49
7.12 "General info" .................................. 50
7.13 "Set Favorites" ................................. 50
7.14 "Settings" ........................................ 51
7.15 "Warning" ........................................ 51
7.16 "TC/ABS"......................................... 52
7.17 "Shift Light" .................................... 53
7.18 Set the time and date....................... 54
7.19 "Fuel Cons"...................................... 55
7.20 "Language" ...................................... 56
7.21 "Distance" ....................................... 56
7.22 "Temp"............................................ 57
7.23 "Extra functions" .............................. 57
7.24 Drive Mode (optional) ....................... 58
8 PREPARING FOR USE................................. 59
8.1 Advice on preparing for first use ........ 59
8.2 Running in the engine ...................... 61
8.3 Loading the vehicle.......................... 61
9 RIDING INSTRUCTIONS.............................. 64
9.1 Checks and maintenance measures
when preparing for use ..................... 64
9.2 Starting the vehicle.......................... 65
9.3 Starting off...................................... 66
9.4 Shifting, riding ................................ 67
TABLE OF CONTENTS
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9.5 Engine braking control (MSR) ............ 72
9.6 Applying the brakes.......................... 72
9.7 Stopping, parking............................. 75
9.8 Transporting.................................... 77
9.9 Refueling ........................................ 78
10 SERVICE SCHEDULE .................................. 80
10.1 Additional information...................... 80
10.2 Required work ................................. 80
10.3 Recommended work ......................... 83
11 TUNING THE CHASSIS ............................... 84
11.1 Adjusting the spring pretension of
the shock absorber ....................... 84
11.2 Adjusting the footrests...................... 85
12 SERVICE WORK ON THE CHASSIS............... 88
12.1 Raising the motorcycle with the rear
lifting gear ...................................... 88
12.2 Removing the rear of the motorcycle
from the lifting gear ......................... 88
12.3 Lifting the motorcycle with the front
lifting gear ...................................... 89
12.4 Taking the motorcycle off the front
lifting gear ...................................... 90
12.5 Removing the passenger seat ............ 91
12.6 Mounting the passenger seat............. 92
12.7 Checking the chain for dirt................ 93
12.8 Cleaning the chain ........................... 93
12.9 Checking the chain tension ............... 95
12.10 Adjusting the chain tension............... 97
12.11 Checking the chain, rear sprocket,
and engine sprocket ......................... 99
12.12 Adjusting the basic position of the
clutch lever ................................... 101
12.13 Checking/correcting the fluid level
of the hydraulic clutch.................... 102
13 BRAKE SYSTEM ....................................... 105
13.1 Antilock brake system (ABS) ........... 105
13.2 Adjusting the basic position of the
hand brake lever ............................ 108
13.3 Checking the brake discs ................ 108
13.4 Checking the brake fluid level of
the front brake............................... 110
13.5 Adding front brake fluid .............. 111
13.6 Checking the front brake linings ...... 114
13.7 Checking the free travel of foot
brake lever .................................... 115
13.8 Adjusting the basic position of the
foot brake lever .......................... 116
13.9 Checking rear brake fluid level ........ 118
TABLE OF CONTENTS
6
13.10 Adding rear brake fluid ............... 119
13.11 Checking the rear brake linings ....... 121
14 WHEELS, TIRES ....................................... 123
14.1 Removing the front wheel ............ 123
14.2 Installing the front wheel ............ 125
14.3 Removing the rear wheel ............. 128
14.4 Installing the rear wheel .............. 131
14.5 Checking the rear hub rubber
dampers .................................... 134
14.6 Checking the tire condition ............. 137
14.7 Checking the tire pressure .............. 139
15 ELECTRICAL SYSTEM ............................... 141
15.1 Removing the battery .................. 141
15.2 Installing the battery ................... 144
15.3 Recharging the battery ................ 146
15.4 Changing the main fuse.................. 149
15.5 Changing the ABS fuses ................. 151
15.6 Changing the fuses of individual
power consumers ........................... 153
15.7 Removing the headlight mask with
the headlight ................................. 157
15.8 Installing the headlight mask with
the headlight ................................. 158
15.9 Changing the headlight bulb ........... 159
15.10 Changing the parking light bulb....... 161
15.11 Changing the turn signal bulb ......... 162
15.12 Checking the headlight setting ........ 164
15.13 Adjusting the headlight range.......... 165
15.14 Diagnostics connector .................... 166
16 COOLING SYSTEM .................................... 167
16.1 Cooling system .............................. 167
16.2 Checking the antifreeze and
coolant level.................................. 168
16.3 Checking the coolant level in the
compensating tank......................... 170
16.4 Draining the coolant ................... 172
16.5 Filling/bleeding the cooling
system ...................................... 174
16.6 Changing the coolant...................... 176
17 TUNING THE ENGINE............................... 180
17.1 Checking the basic position of the
shift lever...................................... 180
17.2 Adjusting the basic position of the
shift lever .................................. 181
17.3 Drive Mode (optional) ..................... 182
17.4 Traction control (optional) (TC)........ 183
TABLE OF CONTENTS
7
18 SERVICE WORK ON THE ENGINE .............. 184
18.1 Checking the engine oil level........... 184
18.2 Changing the engine oil and oil
filter, cleaning the oil screens ...... 185
18.3 Adding engine oil........................... 191
19 CLEANING, CARE ..................................... 194
19.1 Cleaning the motorcycle ................. 194
19.2 Checks and maintenance steps for
winter operation............................. 197
20 STORAGE................................................. 199
20.1 Storage ......................................... 199
20.2 Preparing for use after storage......... 201
21 TROUBLESHOOTING ................................ 202
22 TECHNICAL DATA..................................... 206
22.1 Engine .......................................... 206
22.2 Engine tightening torques ............... 208
22.3 Capacities ..................................... 214
22.3.1 Engine oil ................................. 214
22.3.2 Coolant..................................... 214
22.3.3 Fuel ......................................... 214
22.4 Chassis ......................................... 214
22.5 Electrical system............................ 216
22.6 Tires............................................. 217
22.7 Fork.............................................. 217
22.8 Shock absorber .............................. 218
22.9 Chassis tightening torques .............. 218
23 SUBSTANCES .......................................... 224
24 AUXILIARY SUBSTANCES ......................... 228
25 STANDARDS ............................................ 230
26 INDEX OF SPECIAL TERMS ....................... 231
27 LIST OF ABBREVIATIONS.......................... 232
28 LIST OF SYMBOLS.................................... 233
28.1 Red symbols.................................. 233
28.2 Yellow and orange symbols.............. 233
28.3 Green and blue symbols.................. 234
INDEX ............................................................. 235
1 MEANS OF REPRESENTATION
8
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!
Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary
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.
MEANS OF REPRESENTATION 1
9
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name
®
Indicates a protected name.
Brandâ„¢ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
2 SAFETY ADVICE
10
2.1 Use definition – intended use
This vehicle has been designed and built to withstand the normal stresses and strains of road use.
This vehicle is not suitable for use on race tracks or offroad.
Info
This vehicle is only authorized for operation on public roads in its homologated version.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the
respective use.
2.3 Safety advice
A number of safety instructions need to be followed to operate the model described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
SAFETY ADVICE 2
11
Info
Various information and warning labels are attached in prominent locations on the model described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
2.4 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.
2 SAFETY ADVICE
12
2.5 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 replace-
ment, 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:
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 manufacturer.
2.6 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
SAFETY ADVICE 2
13
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
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.
2.7 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
2 SAFETY ADVICE
14
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.8 Work rules
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals,
sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a thread locker (e.g. Loctite
®
) is required. Apply according to the manufacturer's
instructions.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9 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 conscious-
ness, 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.
SAFETY ADVICE 2
15
2.10 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Own-
er'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 must be handed over to the new owner if the
vehicle is sold.
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website.
International KTM Website: http://www.ktm.com
3 IMPORTANT NOTES
16
3.1 Manufacturer and implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be
recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will
become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not
covered by the warranty.
Additional information on the manufacturer or implied 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 enter the groundwater, the soil, 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.
IMPORTANT NOTES 3
17
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.
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to consider-
ably 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.
3 IMPORTANT NOTES
18
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
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KTM 690 Duke 2018 Owner's manual

Category
Motorcycles
Type
Owner's manual

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