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KTM 2016 690 DUKE R, Owner'S Manual

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KTM 2016 690 DUKE R Owner'S Manual Download Page 162

18

SERVICE WORK ON THE ENGINE

160

Info

Drain the engine oil while the engine is at operating temperature.

H01066-10

Main work

–

Rest the motorcycle on its side stand on a horizontal surface.

–

Place a suitable container under the engine.

–

Remove oil filler plug

with the O-ring from the clutch cover.

K00370-10

–

Remove oil drain plug

with the magnet and seal ring.

–

Completely drain the engine oil.

–

Thoroughly clean the oil drain plug with magnet.

–

Mount and tighten the oil drain plug with the magnet and a new seal ring.
Guideline

Oil drain plug with magnet

M12x1.5

20 Nm
(14.8 lbf ft)

Summary of Contents for 2016 690 DUKE R

Page 1: ...OWNER S MANUAL 2016 690 Duke 690 Duke R Art no 3213397en ...

Page 2: ......

Page 3: ... 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 parti...

Page 4: ...rding 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 TÜV Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen Austria This document is valid for the following models 690 Duke EU F9703P3 F9703P4 690 Duke CN F9787P4 690 Duke R EU F9703P1 690 Duke R AU F9760P1 ...

Page 5: ...RIAL NUMBERS 20 5 1 Chassis number 20 5 2 Type label 20 5 3 Key number 21 5 4 Engine number 22 5 5 Fork part number 22 5 6 Shock absorber article number 23 6 CONTROLS 24 6 1 Clutch lever 24 6 2 Hand brake lever 24 6 3 Throttle grip 25 6 4 Switches on the left side of the handlebar 25 6 4 1 Combination switch 25 6 4 2 Light switch 26 6 4 3 Menu switch 27 6 4 4 Turn signal switch 27 6 4 5 Horn butto...

Page 6: ...7 9 3 Starting off 58 9 4 Shifting riding 58 9 5 Engine braking control MSR 62 9 6 Applying the brakes 63 9 7 Stopping parking 64 9 8 Transport 66 9 9 Refueling 67 10 SERVICE SCHEDULE 69 10 1 Additional information 69 10 2 Required work 69 10 3 Recommended work 71 11 TUNING THE CHASSIS 72 11 1 Fork shock absorber Duke R 72 11 2 Adjusting the compression damping of the fork Duke R 72 11 3 Adjusting...

Page 7: ...level of the front brake 101 13 5 Adding front brake fluid 103 13 6 Checking the front brake linings 105 13 7 Checking the free travel of foot brake lever 106 13 8 Adjusting the basic position of the foot brake lever 107 13 9 Checking rear brake fluid level 109 13 10 Adding rear brake fluid 110 13 11 Checking the rear brake linings 112 14 WHEELS TIRES 113 14 1 Removing the front wheel 113 14 2 Ins...

Page 8: ...reens 159 18 3 Adding engine oil 164 19 CLEANING CARE 166 19 1 Cleaning the motorcycle 166 19 2 Checks and maintenance steps for winter operation 168 20 STORAGE 169 20 1 Storage 169 20 2 Preparing for use after storage 170 21 TROUBLESHOOTING 171 22 TECHNICAL DATA 174 22 1 engine 174 22 2 Engine tightening torques 175 22 3 Capacities 179 22 3 1 Engine oil 179 22 3 2 Coolant 179 22 3 3 Fuel 179 22 4...

Page 9: ...ith 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...

Page 10: ...s document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand 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 ...

Page 11: ...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 missi...

Page 12: ...n Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 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 i...

Page 13: ... 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 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 t...

Page 14: ...ts 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 2 8 Environment If you use your motorcycle responsibly you can ensure that p...

Page 15: ...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 ...

Page 16: ...vironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground 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 hav...

Page 17: ...o 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 s...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example K00345 10 ...

Page 19: ...4 VIEW OF VEHICLE 17 1 Clutch lever p 24 2 Seat 3 Passenger seat 4 Handrails p 32 5 Seat lock p 31 6 Side stand p 35 7 Shift lever p 33 8 Engine number p 22 ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example K00413 10 ...

Page 21: ...p 27 2 Horn button p 28 3 Filler cap 4 Ignition steering lock p 29 5 Emergency OFF switch p 28 5 Electric starter button p 29 6 Hand brake lever p 24 7 Chassis number p 20 8 Fuse box 9 Type label p 20 10 Engine oil level viewer 11 Foot brake lever p 34 12 Passenger footrest p 33 ...

Page 22: ...5 SERIAL NUMBERS 20 5 1 Chassis number 402324 10 The chassis number is stamped on the right side of the steering head 5 2 Type label H01126 01 The type label is located on the right side of the frame ...

Page 23: ...690 Duke R AU Additional type label is located on the left side of the frame 5 3 Key number 402241 10 The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place ...

Page 24: ...S 22 5 4 Engine number 401949 10 The engine number is located on the left side of the engine under the engine sprocket 5 5 Fork part number 402295 10 The fork part number is stamped on the inner side of the fork stub ...

Page 25: ...S 23 5 6 Shock absorber article number 402382 10 Duke Shock absorber article number is on the left side of the shock absorber 402298 10 Duke R Shock absorber article number is located on the rear of the shock absorber ...

Page 26: ...r K00347 10 The clutch lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever K00348 10 Duke The hand brake lever is fitted on the right side of the handlebar ...

Page 27: ...ndlebar The front brake is engaged using the hand brake lever 6 3 Throttle grip K00349 10 The throttle grip is fitted on the right side of the handlebar 6 4 Switches on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left side of the handlebar ...

Page 28: ...t switch H00381 10 Light switch is fitted on the left side of the handlebar Possible states Low beam on Light switch in position In this position the low beam and the tail light are switched on High beam on Push the light switch to position In this position the high beam and the tail light are switched on Headlight flasher Push the light switch into position ...

Page 29: ...utton 6 4 4 Turn signal switch K00350 11 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on Turn signal switch pressed to the left The turn signal switch returns to the center position after activation Right turn signal on Turn signal switch pressed to the right The turn sig nal switch returns to the center position after activati...

Page 30: ...on 6 5 Switches on the right side of the handlebar 6 5 1 Emergency OFF switch K00349 11 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is...

Page 31: ...n steering lock B00925 01 The ignition steering lock is in front of the upper triple clamp Possible states Ignition off In 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 In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignit...

Page 32: ...t occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the envi...

Page 33: ...azard Fuel is highly flammable poisonous and harmful to your health After closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water Remove the ignition key and close the cover 6 8 Seat lock V00043 10 The seat lock is located on the left side of the vehicle It can be locked with...

Page 34: ...t K00414 10 The tool set is located under the passenger seat 6 10 Handrails K00415 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey ...

Page 35: ...ssenger footrests are foldable Possible states Passenger footrest folded in For operation without a passenger Passenger footrest folded out For operation with a passenger 6 12 Shift lever 401950 10 The shift lever is mounted on the left side of the engine ...

Page 36: ...ns can be seen in the photograph The neutral or idle position is between the first and second gears 6 13 Foot brake lever 402177 10 Foot brake lever is located in front of the right footrest The rear brake is engaged with the foot brake lever ...

Page 37: ...and must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand The safety starting system is active Side stand folded in This position is mandatory when riding the motorcycle The safety starting system is inactive ...

Page 38: ... COMBINATION INSTRUMENT 36 7 1 Overview 402644 10 The combination instrument is attached in front of the handlebar The combination instrument is divided into 2 function areas Indicator lamps p 37 Display ...

Page 39: ...rcycle When the ignition is switched on all indicator lamps light up briefly except for the turn signal indicator lamp Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The engine warning lamp lights up yellow The OBD has detected an emission or safety critical fault ...

Page 40: ...or lamp lights up green The transmission has shifted to idle The immobilizer indicator lamp lights up or flashes red Status or error message for immobilizer alarm system The oil pressure warning lamp lights up red The oil pressure is too low The high beam indicator lamp lights up blue The high beam is switched on The general warning lamp lights up yellow An operating safety warning message was det...

Page 41: ... area of the display The time is displayed in 12 hour format if the language is set to EN US Info The time must be reset after the battery was disconnected or the fuse was removed 7 5 Temperature 402647 14 The current ambient temperature is shown in area of the display ...

Page 42: ...play 402647 10 The current gear is shown in area of the display 7 7 Fuel tank capacity 402649 10 The fuel tank contents are shown in area of the display If the fuel level is getting low the last segment flashes Refuel at the next opportunity ...

Page 43: ... bars light up Engine hot six bars light up black 1 to 2 bars light up red Engine very hot all eight bars flash red 7 9 Favorites K00389 01 Press the UP or DOWN button until the Favorites menu appears on the display Pressing the SET button opens the menu Press the UP or DOWN button to select the menu item and activate it with the SET but ton You can directly open five menus in the Favorites menu T...

Page 44: ...ange with the fuel reserve Press and hold the button for 3 5 seconds All entries in the Trip 1 menu are cleared 7 11 Trip 2 K00387 01 Press the UP or DOWN button until the Trip 2 menu appears on the display Trip 2 shows the distance since the last reset such as between two refueling stops Trip 2 runs continuously and counts the distance up to 999 AVG Speed 2 indicates the average speed based on Tr...

Page 45: ...tance covered Battery displays the battery voltage Time displays the current time 7 13 Set Favorites K00429 01 Condition The vehicle is stationary Press the UP or DOWN button until the Set Favorites menu appears on the display Pressing the SET button opens the menu Press the UP or DOWN button to select the menu Press the SET button to set the menu for quick selection The Favorites menu can be conf...

Page 46: ...ts or various values are made in the Settings menu Several functions can be enabled or disabled 7 15 Warning K00388 01 Condition Message or warning Press the UP or DOWN button until the Warning menu appears on the display Pressing the SET button opens the menu Use the UP or DOWN button to navigate through the warnings In the Warning menu warnings that occurred are displayed and stored until they a...

Page 47: ... or DOWN button until the TC ABS menu appears on the display Pressing the SET button opens the menu In the TC ABS menu TC and ABS can be switched off In the ABS Mode menu a choice can be made between Road and SupMot Info After the ignition is switched on traction control and ABS are enabled again When the Road ABS mode is enabled ABS controls both wheels When the SupMot ABS mode is enabled ABS onl...

Page 48: ...tched off completely Press the UP or DOWN button until the MTC ABS menu appears on the display Press ing the SET button opens the menu In the MTC ABS menu MTC and ABS can be switched off In ABS Mode you can select between Road and SupMot Info After the ignition is switched on motorcycle traction control and ABS are enabled again When the Road ABS mode is enabled ABS controls both wheels When the S...

Page 49: ...language The menu languages are US English UK English German Italian French and Spanish 7 19 Distance K00382 01 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the display Pressing the SET button opens the menu Press the UP or DOWN button until the Distance menu is marked on the display Press ing the SET button again sets the unit of measure Selec...

Page 50: ...arked on the display Pressing the SET button again sets the unit of measure Select C or F for the temperature indicator 7 21 Pressure K00391 01 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the display Pressing the SET button opens the menu Press the UP or DOWN button until the Pressure menu is marked on the display Press ing the SET button agai...

Page 51: ...he time and date Condition The motorcycle is stationary K00393 01 Press the UP or DOWN button until the Settings menu appears on the display Pressing the SET button opens the menu Press the UP or DOWN button until the Clock date set menu is marked on the display Pressing the SET button again sets the unit of measure Press the SET button The hour next to Clock flashes Press the UP or DOWN button un...

Page 52: ... Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the display Pressing the SET button opens the menu Press the UP or DOWN button until the Shift Light menu is marked on the display Pressing the SET button again opens the menu Press the UP or DOWN button to select the function Use the SET button to set the engine speed for the gear shift recommendat...

Page 53: ...le on the vehicle K00449 01 Press the UP or DOWN button until the Drive Mode menu appears on the display Press ing the SET button opens the menu Use the UP or DOWN button to navigate through the menu The SET button can be used to select engine and traction control settings that are coordinated with each other SPORT homologated performance with very direct response the traction control allows great...

Page 54: ...ning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteristic Only use tires wheels approved by KTM with the correspon...

Page 55: ... your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 95 Adjust the basic position of the hand brake lever p 100 Adjust the basic position of the foot brake lever p 107 Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible to get a better...

Page 56: ...handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warning Danger of accidents Risk of breakage of suitcase system If you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of...

Page 57: ...ot be burned or singed by the hot exhaust system If you carry luggage make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the maximum permissible weight and the maximum permissible axle loads Guideline Maximum permissible overall weight 350 kg 772 lb Maximum permissible front axle load...

Page 58: ...vel p 109 Check the front brake linings p 105 Check the rear brake linings p 112 Check the brake system function Check the coolant level in the compensating tank p 150 Check the chain for dirt p 88 Check the chain tension p 89 Check the tire condition p 123 Check the tire pressure p 125 Check the settings of all controls and ensure that they can be operated smoothly Check that the electrical equip...

Page 59: ...d engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds B00782 10 Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the position After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time ...

Page 60: ... when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go 9 3 Starting off Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 9 4 Shifting riding Warning Danger of accidents Abrupt...

Page 61: ...g the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal ...

Page 62: ...ng for use Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear Note Engine failure Overheating damages the engine If the coolant temperature warning is displayed stop immediately and take care not to endanger yourself or other traffic parti...

Page 63: ...tle back so it is open This will barely reduce the speed but fuel consumption will be consid erably lower Accelerate only up to a speed suitable for the road surface and weather conditions Par ticularly in bends do not shift and accelerate very carefully Brake if necessary and close the throttle at the same time in order to shift down Pull the clutch lever and shift into a lower gear release the c...

Page 64: ...utch Info When the ABS is switched off or the ABS Mode SupMotis enabled the MSR is not enabled Duke R The MSR is a function of the engine control If the engine braking effect is too great the MSR prevents the rear wheel from locking or sliding away on a sloping position To avoid slip of the rear wheel the MSR only opens the throttle valve as far as abso lutely necessary The MSR is applied on surfa...

Page 65: ...eased the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage Warning Danger of accidents Delayed brake action on salted roads There may be salt ...

Page 66: ...of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not over ...

Page 67: ... stand Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Apply the brakes on the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition key to the position Info If the...

Page 68: ...anger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first 401448 01 Switch off the engi...

Page 69: ...e fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness ...

Page 70: ...10 Switch off the engine Open the filler cap p 30 Fill the fuel tank with fuel up to the lower edge of the filler neck Total fuel tank capacity approx 14 l 3 7 US gal Super unleaded ROZ 95 RON 95 PON 91 p 192 Close the filler cap p 31 ...

Page 71: ...tics tool Check that the electrical system is functioning properly Change the engine oil and oil filter and clean the oil screens p 159 Check the front brake linings p 105 Check the rear brake linings p 112 Check the brake discs p 100 Check the brake lines for damage and leakage Check the rear brake fluid level p 109 Check the free travel of the foot brake lever p 106 Check the shock absorber and ...

Page 72: ...ithout sharp bends Change the air filter Clean the air filter box Check the fuel pressure Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid Check the headlight setting p 146 Check that the radiator fan is functioning properly Final check Check the vehicle for road worthiness and take a test ride Read out the fault memory using the KTM diagnostics tool after...

Page 73: ... the wheel bearing for play Grease all moving parts e g side stand hand lever chain and check for smooth operation Empty the drainage hoses Check all hoses e g fuel coolant bleeder drainage etc and sleeves for cracking leaks and incorrect rout ing Check correct the fluid level of the hydraulic clutch p 96 Check the screws and nuts for tightness Change the coolant One time interval Periodic interva...

Page 74: ...e the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 11 2 Adjusting the compression damping of the fork Duke R Info The hydraulic compression damping determines the fork suspension behavior K00353 10 Turn the white adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the left for...

Page 75: ...ork Duke R Info The hydraulic rebound damping determines the fork suspension behavior V00049 10 Turn the red adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB red adjusting screw The compression damping is located in the left fork leg COMP white adjusting screw Turn counterclockwise ...

Page 76: ...hen riding over an asphalt edge the rear wheel suspension compresses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the low spee...

Page 77: ... Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping during fast compression 11 6 Adjusting the low speed compression damping of the shock absorber Duke R Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled...

Page 78: ...sorber type Guideline Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping during slow to normal compression 11 7 Adjusting the rebound damping of the shock absorber Duke R Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock abso...

Page 79: ...he spring preload of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Info The spring preload defines the initial status of the spring operation on the shock absorber The best spring preload setting is achieved when it is set f...

Page 80: ...06S Info The spring preload can be set to 10 different positions 602558 10 Duke R Measure and note down the spring length in the preloaded state Loosen retaining ring and adjusting ring with the special tool Hook wrench T106S Hook wrench T157S Turn the retaining ring and adjusting ring until the spring is fully relieved of tension Adjust the spring preload by turning adjusting ring Guideline Sprin...

Page 81: ...cer Remove the motorcycle from the work stand Install the footrest bracket 11 9 Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides H00384 10 Remove lock ring Remove the pin of the rider footrest Take off the rider footrest with the spring ...

Page 82: ...G THE CHASSIS 80 V00045 10 Remove screws V00051 01 Adjust the footrest bracket to the desired position V00045 10 Mount and tighten screws Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 ...

Page 83: ...11 TUNING THE CHASSIS 81 H00385 01 Mount the rider footrest with the spring and pin H00384 10 Mount lock ring ...

Page 84: ...ake lever stub Duke R K00437 10 Remove screw and take off foot brake lever stub Position foot brake lever stub at desired hole Guideline Standard Front hole Mount and tighten screw Guideline Screw foot brake lever stub M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 85: ...nt the supports of the lifting gear Insert the adapter in the rear lifting gear Adapter 69329955020 Lifting gear rear 69329955000 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle 12 2 Removing the rear of the motorcycle from the lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on ...

Page 86: ... Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear lifting gear p 83 402345 01 Main work Move the handlebar to the straight ahead position Attach the lifting gear to the steering stem Adapter 61029955620 Lifting gear front 61029055500 Info Always raise the motorcycle at the rea...

Page 87: ...front 12 4 Taking the motorcycle from the front lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 312029 10 Secure the motorcycle against falling over Remove the front lifting gear ...

Page 88: ...12 6 Mounting the passenger seat K00421 10 Hook catches of the passenger seat onto the storage compartment lower the rear and simultaneously push forward Press down the passenger seat until it clicks into place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pullin...

Page 89: ...g the passenger seat cover Duke R Warning Danger of accidents Accident risk caused by the presence of a passenger If the passenger seat cover is mounted the vehicle is not suitable for transporting a passenger Do not ride with a passenger V00074 10 Hook catches of the passenger seat cover onto the storage compartment lower the rear and simultaneously push forward Press down the passenger seat cove...

Page 90: ...their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be di...

Page 91: ...from the lifting gear p 83 12 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of ...

Page 92: ... the vertical rib of the swingarm and measure the chain tension Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain posi tions Chain tension 5 mm 0 2 in If the chain tension does not meet the specification Adjust the chain tension p 91 Finishing work Remove the rear of the motorcycle from the lifting gear p 83 ...

Page 93: ...ion and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise...

Page 94: ... are in the same position relative to the reference marks The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always even Repeat this measurement at different chain posi tions Tighten nuts Make sure that chain adjusters are fitted correctly on adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Finishing work ...

Page 95: ...aratory work Raise the motorcycle with the rear lifting gear p 83 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 96: ...in section Info Chain wear is not always even Repeat this measurement at different chain posi tions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets For safety reaso...

Page 97: ...in sliding guard M6 10 Nm 7 4 lbf ft Loctite 243 Finishing work Remove the rear of the motorcycle from the lifting gear p 83 12 14 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar Th...

Page 98: ...in irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be d...

Page 99: ...int Only use clean brake fluid from a sealed container K00416 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 190 Position the cove...

Page 100: ...Only use spare parts on the brake system which have been approved and recom mended by KTM Only use tires wheels approved by KTM with the corresponding speed index Maintain the specified tire air pressure Service work and repairs must be performed professionally Your authorized KTM workshop will be glad to help Warning Voiding of the government approval for road use and the insurance coverage If th...

Page 101: ... causes a slight pulsing of the hand and foot brake levers ABS warning lamp must light up after the ignition is switched on and go out after start ing off If it does not go out after starting off or if it lights up while riding this indicates a fault in the ABS system In this case the ABS is no longer enabled and the wheels may lock during braking The brake system itself stays functional only ABS ...

Page 102: ...not make any adjustments while riding V00047 11 Duke R Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel Info Push the hand brake lever forward and turn the adjusting wheel Do not make any adjustments while riding 13 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s wi...

Page 103: ... Change the rear brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deformation Change the front brake disc Change the rear brake disc 13 4 Checking the brake fluid level of the front brake Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value ...

Page 104: ... help K00358 10 Duke Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer If the brake fluid has dropped below marking Add front brake fluid p 103 602575 10 Duke R Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer If the brake fluid has dropped below markin...

Page 105: ...ake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental d...

Page 106: ...evel below reser voir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 190 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 602576 10 Duke R Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to the MAX level Brake fluid DOT 4 DOT...

Page 107: ...d braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly M00662 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change ...

Page 108: ... end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not equal the specification Adjust the basic position of the foot brake lever p 107 Attach spring K00443 10 Duke R Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cyli...

Page 109: ...spring Remove screw Loosen nut and turn it back with ball joint until the maximum amount of free travel is reached To adjust the basic position of the foot brake lever to individual requirements loosen nut and turn screw accordingly Info The range of adjustment is limited Turn ball joint as required until free travel is reached If necessary adjust the basic position of the foot brake lever Guideli...

Page 110: ...Disconnect spring Loosen nut and screw in push rod until you have maximum free travel V00055 10 To adjust the basic position of the foot brake lever to individual requirements loosen nut and turn screw accordingly Info The range of adjustment is limited Turn push rod accordingly until you have free travel If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot ...

Page 111: ...ccidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to ...

Page 112: ...system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warni...

Page 113: ... brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 112 V00082 10 Main work Stand the vehicle upright Remove screw cap with membrane Add brake fluid to the MAX marking Brake fluid DOT 4 DOT 5 1 p 190 Mount and tighten the s...

Page 114: ...maged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly C00318 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the ...

Page 115: ... the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever while the brake caliper is removed V00056 10 Duke R Remove screw and pull wheel speed sensor out of the hole Remove screws and spacers Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the br...

Page 116: ...ake discs Always lay the wheel down in such a way that the brake discs are not dam aged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork H00934 12 Remove spacers 14 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency 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 117: ...g life grease p 193 Insert the spacers K00430 10 Clean screw and wheel spindle Grease wheel spindle Long life grease p 193 Lift the front wheel into the fork position it and insert the wheel spindle Info The arrow on the rim near the hub shows the direction of travel The brake disc is located on the left in the direction of travel Mount and tighten screw Guideline Screw front wheel spindle M24x1 5...

Page 118: ...e lever in the acti vated position The brake caliper straightens Tighten screws Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 K00432 10 Duke R Position wheel speed sensor in the drill hole Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake caliper The brake linings are correctly positioned Position spacers Mount screws but...

Page 119: ...e motorcycle from the front lifting gear p 85 Remove the rear of the motorcycle from the lifting gear p 83 K00434 10 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 14 3 Removing the rear wheel Preparatory work Raise the motorcycle with the rear lifting gear p 83 ...

Page 120: ...in adjuster M00666 10 Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward M00667 01 Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage Hold the rear wheel and remove the wheel spindle Pull the rear wheel back until the brake caliper support is suspended freely between the brake ...

Page 121: ...ar wheel is removed 14 4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressu...

Page 122: ...or worn Change the rear wheel bearing Remove spacer Clean and grease shaft seal ring and contact surface of the spacer Long life grease p 193 Insert the spacer Clean and grease the thread of the wheel spindle and nut Long life grease p 193 Clean the mating surfaces of the brake caliper support and swingarm ...

Page 123: ...rrectly on the adjusting screws Tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Position wheel speed sensor in the drill hole Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Operate ...

Page 124: ...eel p 117 602568 10 Main work Check bearing If the bearing is damaged or worn Change the bearing of the rear sprocket carrier Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 602569 11 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the...

Page 125: ... handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteristic Only use tires wheels approved by KTM with the corresponding speed index Warning Danger of a...

Page 126: ...tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 10 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indi cated by the last four digits of the DOT number The first two digits indicate the week of manufacture and the la...

Page 127: ...comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap ...

Page 128: ...y acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Switch off the ignition by turning the ignition key to the position Remove the passenger seat p 86 K00445 11 M...

Page 129: ...15 ELECTRICAL SYSTEM 127 K00446 10 Remove positive terminal cover Disconnect both positive cables from the battery Detach rubber band Pull the battery up and out of the battery holder ...

Page 130: ... Position the battery in the battery holder Battery CBTX9 BS p 181 The battery terminals face opposite the direction of travel Reconnect rubber band Connect both positive cables to the battery Guideline Screw battery terminal M6 2 Nm 1 5 lbf ft Mount positive terminal cover ...

Page 131: ...act with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environment Do not dispose of...

Page 132: ...ife If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The batt...

Page 133: ...and to test the alternator With this device you cannot overcharge the battery Info Never remove lid Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Connect the negative cable with the battery Finishing work Mount the ...

Page 134: ...ed Use only fuses with the prescribed amperage Never bypass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the passenger seat Preparatory work Switch off the ignition by turning the ignition key to the position Remove the passenger seat p 86 K00360 10 Main work Remove protection caps ...

Page 135: ...a burned out fuse wire A spare fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 181 Tip Insert a new spare fuse into the starter relay to have it available when needed K00360 10 Mount protection caps Finishing work Mount the passenger seat p 86 Set the time and date p 49 ...

Page 136: ...ated under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off the ignition by turning the ignition key to the position Remove the passenger seat p 86 K00362 10 To change the fuse of the ABS hydraulic unit Remove the protection cap and fuse Insert a new fus...

Page 137: ...e protection cap Finishing work Mount the passenger seat p 86 15 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located on the right under the fuel tank Preparatory work Switch off the ignition by turning the ignition key to the position V00084 10 Main work Remove screw Remove the trim ...

Page 138: ...trol unit Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10 A for auxiliary equipment permanent positive Fuse 8 10 A for auxiliary equipment accessories connected with ignition switch Fuse 9 10 A ABS Fuse 10 not assigned Fuse SPARE 10 A 15 A spare fuses Info A defective fuse is indicated ...

Page 139: ...pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 182 Fuse 75011088015 p 182 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover V00084 10 Position the trim Mount and tighten screw Guideline Screw fuel spoiler M6 3 Nm 2 2 lbf ft ...

Page 140: ... Removing the headlight mask with the headlight Preparatory work Switch off the ignition by turning the ignition key to the position K00439 10 Main work Duke Remove screws Remove screws K00440 10 Duke R Remove screws Remove screws ...

Page 141: ...AL SYSTEM 139 V00075 10 Fold the headlight mask forward Disconnect plug in connectors Remove the headlight mask 15 8 Installing the headlight mask with the headlight V00075 11 Main work Connect plug in connectors ...

Page 142: ...ining screws chassis M5 5 Nm 3 7 lbf ft Check that the lighting is functioning properly K00440 11 Duke R Position the headlight mask Mount and tighten screws Guideline Screw headlight EJOT 2 Nm 1 5 lbf ft Mount and tighten screws Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft Check that the lighting is functioning properly Finishing work Check the headlight setting p 146 ...

Page 143: ...will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off the ignition by turning the ignition key to the position Remove the headlight mask with the headlight p 138 V00064 10 Main work Duke Unplug connector Remove protection cap ...

Page 144: ... clamp Remove bulb Position the new bulb in the headlight housing Headlight H4 socket P43t p 182 Tabs engage in the recesses Attach retaining clamp V00064 10 Mount protection cap Plug in connector K00441 10 Duke R Unplug connector Remove protection cap ...

Page 145: ...ition the new bulb in the headlight housing Headlight H4 socket P43t p 182 Tabs engage in the recesses Attach retaining clamp K00441 10 Mount protection cap Plug in connector Finishing work Install the headlight mask with the headlight p 139 Check the headlight setting p 146 ...

Page 146: ...the ignition by turning the ignition key to the position Remove the headlight mask with the headlight p 138 V00071 10 Main work Pull cable sleeve and the socket of parking light carefully out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 182 Carefully position socket with the bulb in the housing Mount cable sleeve Finishing work Install...

Page 147: ...urn signal glass Press the bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Lightly push the new lamp into the socket and turn all the way clockwise Turn signal RY10W socket BAU15s p 182 Position the turn signal glass Insert the screw and first turn counterclockwise until...

Page 148: ...e wall at a distance from the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the light dark border does...

Page 149: ...applicable the light dark boundary must be exactly on the lower mark applied in Checking the headlight setting Info Turn counterclockwise to increase the headlight range turn clockwise to reduce the headlight range If you have a payload you may have to correct the headlight range 15 14 Diagnostics connector H00932 11 Diagnostics connector is located under the front rider s seat ...

Page 150: ...lant temperature will not result in a risk of malfunctions 115 C 239 F 100167 10 The coolant is cooled by the air stream and a radiator fan which is controlled by a ther moswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 16 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very...

Page 151: ...dren Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface V00069 11 Main work Remove radiator cap and cap of the compensating tank Check the antifreeze in the coolant 25 45 C 13 49 F If the antifreeze in the coolant does not match the specified value Correct the antifreeze in the coolant Check the coolant level in the compensating tank The coolant leve...

Page 152: ...ss Coolant p 190 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system p 153 Mount radiator cap 16 3 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine...

Page 153: ...out of reach of children Condition The engine is cold The radiator is completely full Preparatory work Park the motorcycle on a horizontal surface V00068 11 Main work Check the coolant level in compensating tank The coolant level must be at the MIN marking If the coolant in the compensating tank is not at the required level but the tank is not empty Remove the cap of the compensating tank Add cool...

Page 154: ... into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold K00379 10 Position the motorc...

Page 155: ...er If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children V00077 10 Remove radiator cap K00444 10 Remove bleeder screw Tilt the vehicle slightly to the right Pour in coolant until it emerges without bubbles at the vent hole and then mount and tighten bleeder screw immediately Coolant 1 20 l 1 27 qt Coolant p 190...

Page 156: ...ent ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until the 5th bar of the temperature indicator lights up Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Check the coolant level in the compensating tank p 150 ...

Page 157: ...to an excessive load 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 155 17 2 Adjusting the basic position of the shift lever H01081 10 Duke ...

Page 158: ... the shift procedure Mount and tighten screw with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 H01082 10 Duke R Loosen nut holding threaded rod Info Nut has a left handed thread Loosen nut holding threaded rod Turn threaded rod to adjust the shift lever Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents ...

Page 159: ...balanced response the traction control allows normal slip on the rear wheel RAIN Homologated performance with soft response for improved driveability the traction control allows normal slip on the rear wheel Various vehicle tunings can be selected in the Drive Mode menu You can choose from SPORT STREET and RAIN The drive mode selected last is displayed in the display Info The drive mode selection ...

Page 160: ...le traction control is switched off the rear wheel may spin during strong acceleration and on surfaces with low grip After the ignition is switched back on motorcycle traction control is enabled again Motorcycle traction control is controlled via the Drive Mode p 157 menu on the combination instrument Motorcycle traction control can be switched off in the MTC ABS menu Info When motorcycle traction...

Page 161: ...rking of the oil level viewer If the engine oil level is not at the specified level Add engine oil p 164 18 2 Changing the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental ...

Page 162: ...ce Place a suitable container under the engine Remove oil filler plug with the O ring from the clutch cover K00370 10 Remove oil drain plug with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with magnet Mount and tighten the oil drain plug with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft ...

Page 163: ...surface K00417 10 Remove screws Remove oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface K00372 10 Insert the new oil filter Oil the O rings of the oil filter covers Position oil filter cover and Mount and tighten the screws Guideline Screw oil filter cover...

Page 164: ...face H00382 10 Remove screw plug with oil screen and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing surface K00418 10 Position oil screen with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite sec tion of the engine case Push the oil screen all the way into the engine case ...

Page 165: ...15 Nm 11 1 lbf ft K00375 10 Position the oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft Fill up with engine oil at the clutch cover Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 190 Alternative engine oil Engine oil SAE 10W 50 p 191 ...

Page 166: ...ust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 159 18 3 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear of the engine H01066 10 Main work Remove filler plug and the O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 190 Engine oil SAE 10W 50...

Page 167: ...c 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 Start the engine and check that it is oil tight Finishing work Check the engine oil level p 159 ...

Page 168: ...cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Seal the exhaust system to keep water out First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a norma...

Page 169: ...nd on the brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 88 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Preserving materials for paints metal and rubber p 194 Treat all painted parts with a mild paint polish Perfect Finish and high gloss polish for paints p 194 Info Do not po...

Page 170: ... Clean the motorcycle p 166 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Treat the engine the swingarm and all other bare ...

Page 171: ...ng for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 193 Refuel p 67 Clean the motorcycle p 166 Change the engine oil and oil filter and clean the oil screens p 159 Check the antifreeze and coolant level p 148 Check the tire pressure p 125 Remove the battery p 126 Recharge the battery p 129 Guideline Storage temperature of battery without direct sunshi...

Page 172: ...e only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 20 2 Preparing for use after storage 401059 01 Take the motorcycle from the front lifting gear p 85 Remove the rear of the motorcycle from the lifting gear p 83 Recharge the battery p 129 Install the battery p 128 Set the time and date p 49 Perform check...

Page 173: ...d the side stand is folded out Shift gear to neutral Engine turns but does not start Operating error Carry out the start procedure p 57 Fuse 3 blown Change the fuses of individual power consumers p 135 The plug in connection of the fuel hose connection is not connected Connect the plug in connection of the fuel line Defect in fuel injection system Read out the fault memory using the KTM diag nosti...

Page 174: ...ights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool N The idle indicator lamp does not light up when the transmission is in neutral Gear position sensor not programmed Read out the fault memory using the KTM diag nostics tool Engine dies during the trip Lack of fuel Refuel p 67 Fuse 1 2 or 3 blown Change the fuses of individual power consumers p ...

Page 175: ...e light and horn are not functional Fuse 5 blown Change the fuses of individual power consumers p 135 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p 135 Set the time and date p 49 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery p 129 Battery is not charged by alternator Check the charging voltage Check the ope...

Page 176: ...ld Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 20 0 25 mm 0 0079 0 0098 in Crankshaft bearing 2 roller bearings Conrod bearing Slide bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 compression ring 1 lower compression ring 1 oil ring with spring expander Engine lubrication Semi dry sump lubrication system with two rotor ...

Page 177: ...plug NGK LMAR7DI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 550 1 650 rpm Starting aid Electric starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clamp intake flange M4 2 5 Nm 1 84 lbf ft Oil nozzle for conrod bearing lubrication M4 2 Nm 1 5 lbf...

Page 178: ...tor cover M6x30 10 Nm 7 4 lbf ft Screw alternator cover chain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 Screw autodecompression M6 3 4 Nm 2 2 3 lbf ft Loctite 243 Screw axial lock of camshaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6x80 10 Nm 7 4 lbf ft Screw camshaft bearing support M6x90 10 Nm 7 4 lbf ft Screw chain shaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw clu...

Page 179: ...M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain guide rail M6x30 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6x30 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 Screws SAS cover M6x12 10 Nm 7 4 lbf ft Loctite 243 Intake channel vacuum connection M6x0 75 2 5 ...

Page 180: ...bf ft Screw plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Screw plug oil channel for oil radiator M10x1 15 Nm 11 1 lbf ft Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft Spark plug outside M10x1 11 Nm 8 1 lbf ft Spark plug inside M12x1 25 18 Nm 13 3 lbf ft Coolant temperature sensor on cylinder head M12x1 5 12 Nm 8 9 lbf ft Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf...

Page 181: ...ming chain tensioner M20x1 5 25 Nm 18 4 lbf ft Plug oil thermostat M24x1 5 15 Nm 11 1 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft 22 3 Capacities 22 3 1 Engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 190 Alternative engine oil Engine oil SAE 10W 50 p 191 22 3 2 Coolant Coolant 1 20 l 1 27 qt Coolant p 190 22 3 3 Fuel Total fuel tank capacity approx 14 l 3 7 US...

Page 182: ...ber Duke R WP Performance Systems 4618 with Pro Lever linkage Suspension travel Duke Front 135 mm 5 31 in Rear 135 mm 5 31 in Suspension travel Duke R Front 150 mm 5 91 in Rear 150 mm 5 91 in Brake system Front Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 320 mm 12 6 in Rear 240 m...

Page 183: ...87 in Seat height unloaded Duke R 865 mm 34 06 in Ground clearance unloaded 192 mm 7 56 in Weight without fuel approx Duke 152 5 kg 336 2 lb Weight without fuel approx Duke R 151 5 kg 334 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 220 kg 485 lb Maximum permissible overall weight 350 kg 772 lb 22 5 Electrical system Battery CBTX9 BS Battery voltage 12 V ...

Page 184: ...0W socket BAU15s 12 V 10 W Turn signal Duke R LED Brake tail light LED License plate lamp LED 22 6 Tires Front tires Rear tires 120 70 ZR 17 M C 58W TL Metzeler SPORTEC M7 RR 160 60 ZR 17 M C 69W TL Metzeler SPORTEC M7 RR Additional information is available in the Service section under http www ktm com 22 7 Fork 22 7 1 Duke Fork part number 05 18 7L 19 Fork WP Performance Systems Up Side Down 4357...

Page 185: ...ROTA SPLIT Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring length with preload spacer s 303 mm 11 93 in Spring rate Medium standard 6 5 N mm 37 1 lb in Air chamber length 80 20 mm 3 15 0 79 in Fork length 831 mm 32 72 in Fork oil per fork leg 534 ml 18 05 f...

Page 186: ...tic sag 20 mm 0 79 in Riding sag 45 mm 1 77 in Fitted length 364 mm 14 33 in 22 8 2 Duke R Shock absorber article number 15 18 7P 11 Shock absorber WP Performance Systems 4618 with Pro Lever linkage Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 cli...

Page 187: ...mm 0 98 in Riding sag 60 65 mm 2 36 2 56 in Fitted length 370 mm 14 57 in Shock absorber fluid Shock absorber fluid SAE 2 5 50180751S1 p 192 22 9 Chassis tightening torques Screw headlight EJOT 2 Nm 1 5 lbf ft Screw side stand switch M4 2 Nm 1 5 lbf ft Loctite 243 Remaining screws chassis M5 5 Nm 3 7 lbf ft Retaining clamp brake line M5 3 Nm 2 2 lbf ft SAS valve screw on frame M5 4 Nm 3 lbf ft Scr...

Page 188: ...h rod foot brake lever M6 6 Nm 4 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw angle sensor M6 5 Nm 3 7 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw battery terminal M6 2 Nm 1 5 lbf ft Screw brake assembly M6 5 Nm 3 7 lbf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw...

Page 189: ...ft rods nut Duke R M6 6 Nm 4 4 lbf ft Shift rods nut Duke R M6LH 6 Nm 4 4 lbf ft Nut manifold on cylinder head M8 20 Nm 14 8 lbf ft Copper paste Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw foot brake lever Duke R M8 20 Nm 14 8 lbf ft Screw foot...

Page 190: ... 2701 Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw foot brake lever Duke M10 25 Nm 18 4 lbf ft Screw handlebar sup...

Page 191: ...ver on swingarm M14x1 5 100 Nm 73 8 lbf ft Nut linkage lever to rocker arm M14x1 5 100 Nm 73 8 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw steering head M20x1 5 40 Nm 29 5 lbf ft Adjusting ring of swingarm bearing M24x1 5 25 Nm 18 4 lbf ft Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Nut steering head M28x1 12 Nm 8 9 lbf ft ...

Page 192: ...LUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 25 45 C 13 49 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil SAE 10W 60 0...

Page 193: ...ification JASO T903 MA p 195 SAE p 195 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Fully synthetic engine oil Recommended supplier Motorex Power Synt 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 195 SAE 4 Guideline Use only oils that comply with the specified stand...

Page 194: ...and that exhibit the corresponding proper ties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E...

Page 195: ... Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean ...

Page 196: ...rex Moto Polish Shine Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 197: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 198: ...h prevents rear wheel locking with excessive engine braking effect by lightly opening the throttle valve MTC Motorcycle Traction Control Auxiliary function of the motor control which reduces engine torque with spinning rear wheel OBD On board diagnosis Vehicle system that monitors emission and safety related values TC Traction Control Auxiliary function of the motor control that reduces engine tor...

Page 199: ...27 LIST OF ABBREVIATIONS 197 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 200: ...ols The engine warning lamp lights up yellow The OBD has detected an emission or safety critical fault ABS warning lamp lights up yellow Status or error messages relating to ABS The ABS lamp flashes if the ABS mode SupMot is enabled The TC lamp lights up yellow The TC or MTC is not available Contact an authorized KTM workshop The TC lamp flashes if TC or MTC actively engage The general warning lam...

Page 201: ...28 LIST OF SYMBOLS 199 The idling speed indicator lamp lights up green The transmission has shifted to idle The high beam indicator lamp lights up blue The high beam is switched on ...

Page 202: ...ings front brake checking 105 rear brake checking 112 Brake system 98 112 Brakes 63 Brakes applying 63 C Capacity coolant 153 179 engine oil 163 179 fuel 68 179 Chain checking 93 cleaning 88 dirt checking for 88 Chain tension adjusting 91 checking 89 Chassis number 20 Clutch fluid level checking correcting 96 Clutch lever 24 basic position adjusting 95 Combination instrument 36 51 ABS 46 Clock Dat...

Page 203: ...raining 152 Coolant level checking 148 checking in the compensating tank 150 Cooling system 148 filling bleeding 153 Customer service 15 D Diagnostics connector 147 E Electric starter button 29 Emergency OFF switch 28 Engine running in 53 Engine braking control 62 Engine number 22 Engine oil adding 164 changing 159 Engine oil level checking 159 Engine sprocket checking 93 Environment 12 F Figures ...

Page 204: ...rails 32 Headlight bulb changing 141 Headlight mask with headlight installing 139 removing 138 Headlight setting adjusting 146 checking 146 Horn button 28 I Ignition lock 29 Implied warranty 14 Indicator lamps 37 Intended use 9 K Key number 21 L Light switch 26 Loading the vehicle 54 Luggage 54 M Main fuse changing 132 Motorcycle cleaning 166 lifting with front lifting gear 84 raising with the rea...

Page 205: ...and vehicle care when preparing for use 56 Protective clothing 12 R Rear hub rubber dampers checking 122 Rear sprocket checking 93 Rear wheel installing 119 removing 117 Refueling fuel 67 Riding 58 starting off 58 S Safe operation 11 Seat lock 31 Service 15 Service schedule 69 71 Shift lever 33 basic position adjusting 155 basic position checking 155 Shifting 58 Shock absorber 72 compression dampi...

Page 206: ...is tightening torques 185 electrical system 181 Engine 174 189 engine tightening torques 175 fork 182 shock absorber 184 tires 182 Throttle grip 25 Time and date setting 49 Tire air pressure checking 125 Tire condition checking 123 Tool set 32 Transport 66 Troubleshooting 171 173 Turn signal bulb changing 145 Turn signal switch 27 Type label 20 U Use definition 9 V View of vehicle front left 16 re...

Page 207: ... 3213397en 3213397en 02 2016 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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