KTM 2009 690 Rally Factory Replica, Owner'S Manual

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CONTENTS
2
CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES ............................................................ 5
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number............................................................... 7
Type label....................................................................... 7
Key number .................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 7
Shock absorber part number............................................. 8
CONTROLS ......................................................................... 9
Clutch lever .................................................................... 9
Hand brake lever ............................................................. 9
Short circuit button ......................................................... 9
Ignition switch ................................................................ 9
Electric starter button ...................................................... 9
Light switch .................................................................. 10
Horn button .................................................................. 10
Flasher switch............................................................... 10
Speedometer................................................................. 10
Speedometer activation and test ..................................... 10
Tripmaster switch .......................................................... 11
Setting kilometers or miles ............................................. 11
Setting the clock ........................................................... 11
Adjusting the speedometer functions............................... 12
Querying the lap time .................................................... 12
SPEED display mode (speed).......................................... 13
Display mode SPEED/H (service hours)............................ 13
Display mode SPEED/CLK (clock) ................................... 13
Display mode SPEED/LAP (lap time) ............................... 13
Display mode SPEED/ODO (odometer) ............................. 14
Display mode SPEED/TR1 (trip master 1) ........................ 14
Display mode SPEED/TR2 (trip master 2) ........................ 14
Disply mode SPEED/A1 (average speed 1) ....................... 15
Display mode SPEED/A2 (average speed 2)...................... 15
Display mode SPEED/S1 (stop watch 1) .......................... 15
Display mode SPEED/S2 (stop watch 2) .......................... 15
Fuses ........................................................................... 16
Fuel tank ...................................................................... 17
Fuel tap........................................................................ 17
Choke........................................................................... 18
Shift lever..................................................................... 18
Foot brake pedal ........................................................... 19
Side stand .................................................................... 19
Steering lock................................................................. 19
Locking the steering ...................................................... 19
Unlocking the steering ................................................... 20
Tool set ........................................................................ 20
Handrail ....................................................................... 20
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION...................................................................... 21
Advice on first use......................................................... 21
Running in the engine.................................................... 22
RIDING INSTRUCTIONS .................................................... 23
Checks before putting into operation ............................... 23
Starting ........................................................................ 23
Starting up ................................................................... 24
Shifting, riding.............................................................. 24
Braking ........................................................................ 24
Stopping, parking .......................................................... 25
Refueling...................................................................... 25
SERVICE SCHEDULE......................................................... 27
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 27
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 28
Important checks and maintenance work to be carried
out by the rider. ............................................................ 28
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 29
Jacking up the motorcycle .............................................. 29
Removing the 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
Adjusting the rebound damping of the shock absorber....... 30
Measuring the unloaded rear wheel sag............................ 30
Checking the static sag of the shock absorber .................. 31
Checking the riding sag of the shock absorber .................. 31
Adjusting the spring preload of the shock absorber
x ...... 31
Checking the riding sag of the shock absorber .................. 32
Adjusting the riding sag
x
............................................. 32
Removing the shock absorber ......................................... 33
Installing the shock absorber .......................................... 33
Checking basic setting of fork ......................................... 34
Adjusting the compression damping of the fork ................ 34
Adjusting the rebound damping of the fork....................... 35
Bleeding fork legs.......................................................... 35
Cleaning dust boots of fork legs ...................................... 35
Dismounting the front fender .......................................... 36
Installing the front fender............................................... 36
Checking play of steering head bearing............................ 36
Adjusting play of steering head bearing
x ....................... 37
Fork offset .................................................................... 38
Handlebar position ........................................................ 38
Adjusting the handlebar position
x ................................ 39
Adjusting the Bowden cable ........................................... 40
Checking chain dirt ....................................................... 40
Cleaning the chain......................................................... 40
Checking the chain tension ............................................ 40
Checking the rear sprocket/engine sprocket for wear ......... 41
Adjusting chain tension.................................................. 41
Adjusting basic setting of clutch lever ............................. 42
Checking the fluid level of the hydraulic clutch ................ 42
Checking the brake discs................................................ 42
Checking free play of hand brake lever............................. 43
Adjusting free travel of handbrake lever ........................... 43
Checking the front brake fluid level ................................. 43
Adding front brake fluid
x
............................................ 44
Checking the front brake linings...................................... 44
Removing front brake linings
x
..................................... 45
Installing the front brake linings
x
................................. 45
Changing the front brake linings
x
................................. 46
Checking free play of foot brake lever .............................. 47
Adjusting free travel of foot brake pedal
x
...................... 47
Checking rear brake fluid level........................................ 47
Adding rear brake fluid
x
.............................................. 48
Checking the rear brake linings ....................................... 48
Removing rear brake linings
x
....................................... 49
Installing the rear brake linings
x
.................................. 49
Changing the rear brake linings
x
.................................. 50
Removing front wheel
x
................................................ 51