KTM 2009 690 Rally Factory Replica Owner'S Manual Download

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OWNER'S MANUAL

2009

690 Rally Factory Replica

ART. NO. 3211361en

Summary of Contents for 2009 690 Rally Factory Replica

Page 1: ...OWNER S MANUAL 2009 690 Rally Factory Replica ART NO 3211361en...

Page 2: ......

Page 3: ...e technical specifica tions 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 produ...

Page 4: ...e motorcycle from the work stand 29 Checking the basic chassis setting with the rider s weight 29 Compression damping of shock absorber 29 Adjusting the compression damping of the shock absorber 29 Ad...

Page 5: ...or idle 65 Carburetor adjusting the idle speed x 66 Checking the engine oil level 67 Changing engine oil and filter cleaning oil screens x 67 Draining the engine oil x 67 Removing the oil filter x 68...

Page 6: ...hnical 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 speci...

Page 7: ...aims will be recognized No warranty claims can be granted for damage resulting from manipulations and or alterations to the vehicle Fuel oils etc You should use the fuels oils and greases according to...

Page 8: ...ill 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...

Page 9: ...1 11 Type label is fixed to the right of the steering head 3 3 Key number 500125 10 The key number is stamped on the key strap 3 4 Engine number 600003 10 The engine number is stamped on the left side...

Page 10: ...LOCATION OF SERIAL NUMBERS 8 3 6 Shock absorber part number 600026 10 Shock absorber part number is attached at the shock absorber unit to the rear of the direction of travel...

Page 11: ...ion switch 600044 10 The ignition switch is located to the left of the indicator lamp on the instrument support Possible states Ignition off Ignition switch flipped up In this position the ignition ci...

Page 12: ...sher switch 600004 10 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher switch is in the central position Flasher light left on Flasher switch tu...

Page 13: ...display Press the button for 3 5 seconds The Setup menu opens and the active functions are displayed Press the button repeatedly until the Km h Mph display flashes Km h adjusting Press the button Mph...

Page 14: ...changes to the next func tion Deactivating a function Press the button The icon disappears from the display and the display changes to the next function Activate or deactivate all functions accordingl...

Page 15: ...y changes to the ODO display mode The H display mode is suppressed during the journey Press the button No function Press the button No function Press the button for 3 5 seconds The display changes to...

Page 16: ...led with A1 average speed 1 and S1 stop watch 1 Info If 999 9 is exceeded the values of TR1 A1 and S1 are automaticallt reset to 0 0 Press the button No function Press the button No function Press the...

Page 17: ...on No function Press the button No function Press the button for 3 5 seconds Press the button briefly Next display mode 4 25 Display mode SPEED S1 stop watch 1 400327 01 Press the button briefly and r...

Page 18: ...trip master 2 Increases value of TR2 Reduces value of TR2 Deletes value of TR2 Next display mode Disply mode SPEED A1 average speed 1 No function No function Displays of TR1 A1 and S1 are reset to 0...

Page 19: ...at 600045 10 The right fuel tank is filled via filler cap and the left fuel tank is filled via filler cap 600046 10 The rear fuel tank is filled via filler cap 4 29 Fuel tap 600008 10 Fuel tap is loca...

Page 20: ...vating the choke function frees an opening through which the engine can draw extra fuel This gives a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke funct...

Page 21: ...nly The side stand and or the frame could be damaged and the motorcycle could fall over To park the motorcycle remove the rubber band fold down the side stand with your foot and rest the motorcycle ag...

Page 22: ...ering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock 4 37 Tool set 600805 10 The tool set i...

Page 23: ...not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never le...

Page 24: ...missible front axle load 190 kg 419 lb Maximum permissible rear axle load 250 kg 551 lb Run the engine in 5 2 Running in the engine During the run in phase do not exceed the specified speed in the res...

Page 25: ...nd can 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 a closed space without an effective exhaust...

Page 26: ...Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake if necessary and close the throttle at the same time Pull the clu...

Page 27: ...side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Apply the brakes and shift into neutral With the engine idling flip the ignition switch up until th...

Page 28: ...l tank half front right approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Rear fuel tank approx 18 0 l 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Total fuel capacity approx 3...

Page 29: ...les for damage and routing without sharp bends Clean the fuel tank breather hoses checking for damage and routing with out sharp bends Check the headlamp setting Treat electric contacts with contact s...

Page 30: ...components including shafts x Check the crankshaft connecting rod and cylinder x Check the clutch x Check the camshaft rocker arm and valves x K100A every 10 000 km 6 214 mi J1A annually J2A every 2...

Page 31: ...your weight is above or below the standard range you have to adjust the basic setting of the suspension components accord ingly Small weight differences can be compensated by adjusting the spring pre...

Page 32: ...rber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself 600053 10 Turn adjusting scr...

Page 33: ...full protective clothing in a normal sitting position feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between...

Page 34: ...ition feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between the rear axle and a fixed point Make a note of...

Page 35: ...ews and splash protector 600094 10 Remove screw 600095 10 Remove screw Remove shock absorber 8 14 Installing the shock absorber 600096 10 Position the shock absorber Mount the screw with the washers a...

Page 36: ...compensated by the spring preload However if your fork is often overloaded hard end stop on compression you must fit harder springs to avoid damage to the fork and frame 8 16 Adjusting the compressio...

Page 37: ...ove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the work stand p 29 8 19 Cleaning dust boots of fork le...

Page 38: ...ing the bearing and the bearing seats in the frame can be damaged after time Jack up the motorcycle p 29 Remove the steering damper 400189 10 Move the handlebar to the straight ahead position Move the...

Page 39: ...ring head M20x1 5 12 Nm 8 9 lbf ft Lock the screw and nut Guideline Lock nut top steering head M20x1 5 25 Nm 18 4 lbf ft 600100 12 Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft...

Page 40: ...in drill hole you will achieve better riding stability on fast stretches Fork offset No mark 22 mm 0 87 in 8 25 Handlebar position 0 0 B B 0 0 A A 400361 10 On the upper triple clamp there are 2 holes...

Page 41: ...nt and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Condition Spacer mounted Use a M10x35 screw Condition Without a spacer Use a M10x25 screw Info Positio...

Page 42: ...ental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info The service life of the chain d...

Page 43: ...e of the joint faces forward riding direction The engine sprocket rear sprocket and chain should always be replaced together Check the chain guides for firm seating and wear 8 32 Adjusting chain tensi...

Page 44: ...s Remove the cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level of the hydraulic...

Page 45: ...dlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do...

Page 46: ...tal hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This...

Page 47: ...ke caliper support 8 42 Installing the front brake linings x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and...

Page 48: ...authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulati...

Page 49: ...pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications 400291 13 Loosen the nut and use...

Page 50: ...Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil sea...

Page 51: ...brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Bra...

Page 52: ...ronmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake flui...

Page 53: ...ce bushing 8 53 Mounting the front wheel x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with br...

Page 54: ...when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster 600036 10 Withdraw the wheel spindle only enough to allow the rear wheel...

Page 55: ...ttach the chain 600114 10 Position the chain adjuster Mount nut but do not tighten it yet Adjust the chain tension p 41 Operate the foot brake lever repeatedly until the brake linings lie on the brake...

Page 56: ...air pressure on road Front 1 5 bar 22 psi Rear 1 5 bar 22 psi If the tire pressure does not meet specifications Correct tire pressure Mount dust cap 8 58 Checking spoke tension Warning Danger of acci...

Page 57: ...trim at the guides and Info When positioning the trim exercise caution with the quick releases to ensure that you do not damage the trim 600081 11 Align the trim and attach it with the quick releases...

Page 58: ...and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is...

Page 59: ...and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clot...

Page 60: ...el tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fu...

Page 61: ...th sides but do not tighten it yet Align the main silencer Mount and tighten screws and on both sides Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Tighten screw on both sides Guideline Rema...

Page 62: ...e with a rider the light dark boundary must lie exactly on the lower mark If the light dark boundary does not meet specifications Adjust the headlamp p 60 8 70 Adjusting the headlamp Remove the trim p...

Page 63: ...d tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Attach the plus cable and replace the plus pole cover Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Attach the minus ca...

Page 64: ...to avoid damage to the motor cycle s electronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to...

Page 65: ...in eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor imm...

Page 66: ...coolants out of the reach of children 600067 10 Condition Engine is cold Stand the motorcycle upright on a horizontal surface Remove compensating tank cap and the radiator cap Check antifreeze of coo...

Page 67: ...the front of the air filter box and swing down 600803 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 56 8 80 Carburetor idle The idle setting of t...

Page 68: ...ghest idle speed Info If there is a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extreme sport motorcyclist will set the mixture about 1 4 of a turn bac...

Page 69: ...l x p 70 Mount the motor guard p 59 8 84 Draining the engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gl...

Page 70: ...leaning substances brake fluid batteries etc according to regulations Remove the front fuel tank p 56 Place a suitable container under the engine 600083 10 Remove screws Take off the oil filter cover...

Page 71: ...e filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine 600077 10 Remove plug with oil screen and O ring 600079 10 Remove plug...

Page 72: ...ft Install the fuel tank p 56 8 88 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 600060 11 Remove the screw cap on the clu...

Page 73: ...ngine oil SAE 20W 60 p 96 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend making an oil change in this case Mount and tighten screw cap Danger Dang...

Page 74: ...generator x Check the generator x Socket connector of CDI control device pulse generator or ignition coil oxidized Clean the socket connector and treat it with contact spray Water in carburetor or jet...

Page 75: ...k breathers Check the fuel filter Check the fuel sieve of the fuel tanks Clean the fuel tap Check adjust the carburetor components x Check the fuel pump x Air filter very dirty Clean the air filter x...

Page 76: ...e cleaner and a soft sponge If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After the motorcycle has been thoroughly cleaned wi...

Page 77: ...nge the engine oil and filter clean the oil screens x p 67 Check the coolant level and antifreeze p 64 Drain the fuel from the tanks into a suitable container Drain the fuel from the carburetor into a...

Page 78: ...rotor pumps Primary transmission 36 79 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 23 26 5th gear 24 25 6th ge...

Page 79: ...hain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw large clutch cover M6 10 Nm 7 4 lbf ft Screw locking lever M6 10 Nm 7 4 lbf...

Page 80: ...r for temperature switch on cylinder head M12x1 5 12 Nm 8 9 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil...

Page 81: ...ry Replica Carburetor type KEIHIN FCR MX 41 Carburetor identification number 4100C Needle position 5 th position from top Idle mixture adjusting screw Open 2 turns Main jet 160 Jet needle OBDYU OBEKR...

Page 82: ...Secondary drive ratio 16 44 Rear sprockets available 43 44 45 Chain 5 8 x 1 4 Wheelbase 1 535 10 mm 60 43 0 39 in Steering head angle 62 5 Seat height unloaded 980 mm 38 58 in Ground clearance unloade...

Page 83: ...com 15 3 Capacity fuel Fuel tank capacity Fuel tank half front left approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Fuel tank half front right approx 9 0 l 2 38 US gal Super unleaded...

Page 84: ...preload spacer s 502 mm 19 76 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 8 N mm 27 4 lb in Weight of rider 75 85 kg 165 187 lb 5 0 N mm 28 6 lb in Gas pressure 1 8 bar 26 psi Fork length 95...

Page 85: ...g Standard 20 clicks Spring preload Standard 14 mm Spring rate Weight of rider 65 75 kg 143 165 lb 88 N mm 502 lb in Weight of rider 75 85 kg 165 187 lb 92 N mm 525 lb in Weight of rider 85 95 kg 187...

Page 86: ...ing screws chassis M8 25 Nm 18 4 lbf ft Screw beam engine support bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw foot brake pedal M8 25 Nm 18 4 lbf ft Loc...

Page 87: ...85...

Page 88: ...M A _ C 2 R A _ C 2 S 1 3 2 A 0 1 1 2 2 F A 0 1 1 2 3 F A 0 1 1 2 4 F A 0 1 1 2 5 F A 5 1 1 2 6 F A 5 1 2 7 F A 5 1 2 8 F A 0 1 1 2 1 F 5 X 6 D 3 2 4 3 1 M 0 3 A 4 F A _ C 1 M 1 G 1 K 4 2 3 1 U C_AU...

Page 89: ...tarter button Cable colors 1 Green 2 Green 3 Green 4 Green 5 Green 6 Green 7 Yellow red 8 Green 9 Yellow red 10 Yellow red 11 Yellow red 12 Yellow red 13 Yellow red 14 Yellow red 15 Orange 16 Black or...

Page 90: ...ack yellow 52 Brown 53 Brown 54 Brown 55 Brown 56 Black 57 Black red 58 Black red 59 White green 60 Black green 61 Green red 62 Pink 63 Orange 64 White red 65 Yellow blue 69 Brown 131 Yellow 133 Black...

Page 91: ...WIRING DIAGRAM 89...

Page 92: ...1 7 D 1 3 9 0 1 5 C 1 0 4 3 1 2 L A _ C 2 T A _ C 1 L 1 2 3 M A _ C 3 R A _ C 1 B 2 1 3 t 2 B 1 1 2 L 1 3 2 4 5 6 8 7 9 0 1 1 1 6 1 5 1 4 1 3 1 2 1 6 1 BX _ C 6 A 1 BJ _ C 1 AY _ C 6 X 1 1 2 37 38 0...

Page 93: ...Throttle position sensor B2 Temperature switch for indicator lamp L1 Pulse generator L2 Ignition coil Cable colors 15 Orange 32 Brown 33 Brown 34 Blue 35 Yellow 36 Black 37 Gray 38 black blue 39 Gray...

Page 94: ...2 H6 1 2 H10 1 2 H8 1 2 H7 C_DI 2 1 2 9 1 H 1 2 8 1 H 1 2 7 1 H 1 2 6 1 H 1 2 5 1 H 3 C 1 7 1 3 1 3 0 3 X 7 0 4 X I H O L t h g i l P 4 3 2 1 5 1 6 C A _ C 1 A B _ C 1 F B _ C 6 C B _ C 9 S 6 C 1 2 4...

Page 95: ...light optional H15 Flasher indicator light H16 Idling speed indicator lamp H17 Indicator lamp for the coolant temperature H18 High beam indicator light H19 Oil pressure indicator lamp K2 Flasher rela...

Page 96: ...olet 81 Violet 82 Black 83 Black 84 Black 85 Black 86 Black 87 Black 88 Black 89 Black 90 Green white 91 Brown 92 White 93 Black brown 94 White yellow 95 White 96 White 97 White 98 Brown 99 Brown 100...

Page 97: ...WIRING DIAGRAM 95 116 White 117 White 118 White 119 Brown 120 Brown 121 Brown 122 Brown 123 Brown 124 Brown 125 Brown 126 Brown 127 Black yellow 128 Black green 129 Red 130 Brown...

Page 98: ...rrosion antifreeze 50 Distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 99 SAE p 99 SAE 10W 60...

Page 99: ...ine Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Mot...

Page 100: ...upplier Motorex Accu Contact High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Specification KTM recommends Motorex products Supp...

Page 101: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wit...

Page 102: ...level 42 Clutch lever 9 adjusting 42 Compression damping fork adjusting 34 Coolant level checking 63 Coolant level and antifreeze checking 64 D Dust boots cleaning 35 E Electric starter button 9 Engin...

Page 103: ...6 removing 55 Service schedule 27 28 Shift lever gears 18 Shifting riding 24 Shock absorber adjusting the spring preload 31 compression damping adjusting 29 rebound damping adjusting 30 removing 33 st...

Page 104: ...3211361en 3211361en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 08 2008 Photo Mitterbauer...

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KTM 2009 690 Rally Factory Replica, Owner'S Manual

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