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KTM 690 DUKE MAL, Owner'S Manual, Page: 98 / 197

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KTM 690 DUKE MAL Owner'S Manual Download Page 98

12

BRAKE SYSTEM

96

602583-10

(Duke)

–

Check the brake linings for minimum thickness

A

.

Minimum thickness

A

≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings.

x

–

Check the brake linings for damage and cracking.
» If there is damage or cracking:

–

Change the front brake linings.

x

602580-10

(Duke R)

–

Check the brake linings for minimum thickness

A

.

Minimum thickness

A

≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings.

x

–

Check the brake linings for damage and cracking.
» If there is damage or cracking:

–

Change the front brake linings.

x

12.7

Checking the free travel of foot brake lever

Warning

Danger of accidents

 

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over-
heating. Adjust the free travel on foot brake lever according to specifications.

Summary of Contents for 690 DUKE MAL

Page 1: ...OWNER S MANUAL 2013 690 Duke EU 690 Duke AUS UK 690 Duke MAL 690 Duke R EU 690 Duke R AUS UK 690 Duke R MAL Art no 3211953en...

Page 2: ......

Page 3: ...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 producti...

Page 4: ...DEAR KTM CUSTOMER 2 KTM Sportmotorcycle AG 5230 Mattighofen Austria...

Page 5: ...ype label 20 5 3 Key number 21 5 4 Engine number 22 5 5 Fork part number 23 5 6 Shock absorber part number 23 6 CONTROLS 25 6 1 Clutch lever 25 6 2 Hand brake lever 25 6 3 Throttle grip 26 6 4 Horn bu...

Page 6: ...5 Adjusting the high speed compression damping of the shock absorber Duke R 68 10 6 Adjusting the low speed compression damping of the shock absorber Duke R 69 10 7 Adjusting the rebound damping of th...

Page 7: ...moving the battery x 116 14 2 Installing the battery x 117 14 3 Recharging the battery x 118 14 4 Changing the main fuse 121 14 5 Changing the ABS fuses 123 14 6 Changing the fuses of individual power...

Page 8: ...NK CODE 160 22 TECHNICAL DATA 167 22 1 engine 167 22 2 Engine tightening torques 168 22 3 Capacities 171 22 3 1 Engine oil 171 22 3 2 Coolant 172 22 3 3 Fuel 172 22 4 Chassis 172 22 5 Electrical syste...

Page 9: ...standing 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...

Page 10: ...he 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...

Page 11: ...n Warning Identifies 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 p...

Page 12: ...hem 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 exh...

Page 13: ...s 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...

Page 14: ...hen 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...

Page 15: ...ccessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain...

Page 16: ...ipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Plea...

Page 17: ...15...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example C00298 10...

Page 19: ...4 VIEW OF VEHICLE 17 1 Clutch lever p 25 2 Seat 3 Passenger seat 4 Handrails p 42 5 Seat lock p 41 6 Engine number p 22 7 Shift lever p 43 8 Side stand p 46...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example C00299 10...

Page 21: ...itch p 28 2 Turn signal switch p 28 2 Horn button p 27 3 Filler cap 4 Ignition steering lock p 30 5 Emergency OFF switch p 29 5 Electric starter button p 29 6 Hand brake lever p 25 7 Chassis number ty...

Page 22: ...is number 602542 10 The chassis number 1 is stamped on the right side of the steering head 5 2 Type label C00301 10 690 Duke EU 690 Duke MAL 690 Duke R EU 690 Duke R MAL The type label 1 is located on...

Page 23: ...S UK 690 Duke R AUS UK The type label 1 is located on the left side of the frame 5 3 Key number B00755 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare...

Page 24: ...Engine number C00302 10 Duke The engine number 1 is located on the left side of the engine under the engine sprocket 602550 10 Duke R The engine number 1 is located on the left side of the engine und...

Page 25: ...5 5 Fork part number C00303 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber part number C00304 10 Duke The shock absorber part number 1 is on the left side o...

Page 26: ...5 SERIAL NUMBERS 24 602551 10 Duke R The shock absorber part number 1 is found on the damper at the rear...

Page 27: ...00305 10 The clutch lever 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever 602570 10 Duke The hand brake lever 1 is fitted on...

Page 28: ...Duke R The hand brake lever 1 is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever 6 3 Throttle grip B00922 10 The throttle grip 1 is fitted on the right...

Page 29: ...ssed The horn is operated in this position 6 5 Light switch C00307 10 The light switch 1 is fitted on the left side of the handlebar Possible states Low beam on Light switch is turned downwards In thi...

Page 30: ...l switch C00308 10 The turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on The turn signal switch is pressed to the left The turn signa...

Page 31: ...ted 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 closed 6 9 Electric starter button 602553 11 The...

Page 32: ...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 ignition circuit is interrupted and the steering locked Th...

Page 33: ...1 trip master 2 TRIP 2 and gear display GEAr Press the SET button 2 to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 The ABS can be switched off using button 3 6 11...

Page 34: ...igh beam is switched on The temperature warning lamp lights up red The coolant temperature has reached a critical value The low fuel warning lamp lights up orange The fuel level has reached the reserv...

Page 35: ...up for one second as a function check 400881 01 LEnGth Following the display function check the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumference of the...

Page 36: ...s shown in kilometers per hour km h or in miles per hour mph 6 11 7 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting accor...

Page 37: ...the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 6 11 8 Time 401443 11 The time is shown in area 1 of the display Info After rec...

Page 38: ...n and the SET button pressed simultaneously The time is set 6 11 10 ODO display 401444 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retaine...

Page 39: ...IP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999...

Page 40: ...mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 6 11 1...

Page 41: ...nd always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if th...

Page 42: ...igni tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap 6 13 Closing the filler cap B00927 01 Fold down the filler cap Turn the ignition key 90 clockwise Press down the...

Page 43: ...ROLS 41 6 14 Seat lock B00928 10 The seat lock 1 is located on the left side of the vehicle It can be locked with the ignition key 6 15 Tool set B00929 10 The tool set 1 is located under the passenger...

Page 44: ...have a passenger the passenger can hold on the handrails during the journey 6 17 Passenger footrests B00931 01 The passenger footrests can be folded up and down Possible states Passenger footrests fo...

Page 45: ...6 CONTROLS 43 6 18 Shift lever 602555 11 Duke The shift lever 1 is mounted on the left side of the engine 602554 11 Duke R The shift lever 1 is mounted on the left side of the engine...

Page 46: ...ar positions can be seen in the figure The neutral or idle position is between the first and second gears 602554 10 Duke R The gear positions can be seen in the figure The neutral or idle position is...

Page 47: ...ot brake lever C00313 10 Duke Foot brake lever 1 is located in front of the right footrest 602556 10 Duke R Foot brake lever 1 is located in front of the right footrest The rear brake is engaged with...

Page 48: ...r parking the motorcycle Info The side stand 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 f...

Page 49: ...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...

Page 50: ...t trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 87 Adjust the basic position of the hand brake lever p 90 Adjust the ba...

Page 51: ...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 mp...

Page 52: ...cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion betwe...

Page 53: ...el p 100 Check the front brake linings p 95 Check the rear brake linings p 103 Check the brake system function Check the coolant level in the compensating tank p 137 Check the chain for dirt p 80 Chec...

Page 54: ...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 turni...

Page 55: ...quipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you sh...

Page 56: ...a low gear at high engine speed The engine races and the rear wheel can lock up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key positi...

Page 57: ...face must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in Warning Danger of accide...

Page 58: ...failure Info If unusual noises arise during operation stop immediately park the vehicle properly and contact an authorized KTM workshop 602555 10 Duke When conditions allow incline road situation etc...

Page 59: ...rn the throttle 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...

Page 60: ...system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system If the foot brake lever is not released the brake linings drag...

Page 61: ...the front and rear brakes at the same time Info When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the tires Wa...

Page 62: ...g work on them Note Danger 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...

Page 63: ...foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to the position and turning it to the posi tion To make...

Page 64: ...tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel...

Page 65: ...the engine Open the filler cap p 39 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 14 l 3 7 US gal Super unleaded ROZ 95 RON 95 PON 91 p 185 Clo...

Page 66: ...lines for damage and leakage Check the rear brake fluid level p 100 Check the free travel of the foot brake lever p 96 Check the shock absorber and fork for leaks Check the swingarm bearing x Check th...

Page 67: ...x Check rectify the fluid level of the hydraulic clutch p 88 Check the screws and nuts for tightness x Change the front brake fluid x Change the rear brake fluid x Check the clutch x Check the headlig...

Page 68: ...ange the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 Adjusting the compression damping of the fork Duke R Inf...

Page 69: ...ke R Info The hydraulic rebound damping determines the fork suspension behavior 602572 10 Turn the red adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the...

Page 70: ...anding after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slow...

Page 71: ...sorber type 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...

Page 72: ...ng to the shock absorber 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 countercl...

Page 73: ...g preload of the shock absorber x Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to g...

Page 74: ...ne Spring preload Standard 4 clicks Hook wrench T106S Info The spring preload can be set to 10 different positions 602558 10 Duke R Release retaining ring 1 Hook wrench T106S Turn adjusting ring 2 to...

Page 75: ...e shock absorber x Install the main silencer x Remove the motorcycle from the work stand 10 9 Adjusting the footrests C00329 10 Remove lock ring 1 Remove the pin of the rider s footrest Take off the r...

Page 76: ...331 01 Adjust the footrest bracket to the desired position C00330 10 Mount and tighten screws 2 Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 C00332 01 Mount the rider s foot...

Page 77: ...10 TUNING THE CHASSIS 75 C00329 10 Mount lock ring 1 Repeat the operations on the opposite side...

Page 78: ...1 Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm...

Page 79: ...d 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 wheel stand p 76 602543 01...

Page 80: ...away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the front wheel stand 11 5 Removing the passenger seat B00928 10 Insert the ign...

Page 81: ...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 pulling up Finally check that the passenger...

Page 82: ...ansporting a passenger Do not ride with a passenger 602560 10 Hook catches 1 of the passenger seat cover onto the storage compartment lower the rear and simultaneously push forward Press down the pass...

Page 83: ...nd 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 dispo...

Page 84: ...ansmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct...

Page 85: ...t rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On...

Page 86: ...e markings on the left and right chain adjusters 4 are in the same position relative to the reference marks C The rear wheel is then correctly aligned Info The upper chain section must be taut Chain w...

Page 87: ...cket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket or engine sprocket x Info The engine...

Page 88: ...n section Info Chain wear is not always even Repeat this measurement at different chain posi tions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the...

Page 89: ...6 10 Nm 7 4 lbf ft Loctite 243 11 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 t...

Page 90: ...d B00944 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm...

Page 91: ...roved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels whe...

Page 92: ...heels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and t...

Page 93: ...ents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 100135 10 Check the thickness of the front and rea...

Page 94: ...t the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your autho rized KTM workshop will be glad to help Warning Danger of...

Page 95: ...brake linings are completely worn down Check the brake system and do not continue riding Your autho rized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritati...

Page 96: ...ke fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 95 B00948 10 Main work Duke Move the brake flui...

Page 97: ...ke fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your aut...

Page 98: ...inimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x Check the brake linings for damage and cracking If there is damage...

Page 99: ...brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free trave...

Page 100: ...ent is limited Turn ball joint 5 as required until free travel A is reached If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in...

Page 101: ...ke lever to individual requirements loosen nut 4 and turn screw 5 accordingly Info The range of adjustment is limited Turn push rod 3 accordingly until you have free travel A If necessary adjust the b...

Page 102: ...f 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 w...

Page 103: ...e 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...

Page 104: ...ines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the...

Page 105: ...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 brak...

Page 106: ...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 602562 10...

Page 107: ...Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 13 2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease o...

Page 108: ...the hole Mount and tighten screw 4 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake caliper and check that the brake linings are seated correctly Position spacers 5 Mount scr...

Page 109: ...ngs are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the acti vated position The brake calipers straighten Tighten screws 6 Guideline Screw front brake cali...

Page 110: ...torcycle with the rear wheel stand p 76 602563 10 Main work Remove screw 1 and pull wheel speed sensor 2 out of the hole Remove nut 3 Remove chain adjuster 4 602564 10 Pull out wheel spindle 5 to the...

Page 111: ...Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed 13 4 Installing the rear wheel x Warning...

Page 112: ...Replace the wheel bearing x Remove bushing 1 Clean and grease the mating surfaces of the bushings and the shaft seal rings Long life grease p 188 Install the bushing Clean and grease the thread of the...

Page 113: ...he adjust ing screws and tighten the 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 r...

Page 114: ...108 602568 10 Main work Check bearing 1 If the bearing is damaged or worn Replace the bearings x Check rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the rear hub are da...

Page 115: ...terns 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 Uncontrollable ha...

Page 116: ...Info Note local national regulations concerning the minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum permissible depth Change the tires Check the age of...

Page 117: ...omfort 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 pressu...

Page 118: ...ttery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets i...

Page 119: ...up and out of the battery holder 14 2 Installing the battery x B00963 11 Main work Position the battery in the battery holder Info The terminals of the battery must face in the direction of travel At...

Page 120: ...oid contact with battery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If...

Page 121: ...he charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle...

Page 122: ...d start potential of the battery and to test the alternator With this device you cannot overcharge the battery Info Never remove lid 1 Switch off the charger after charging Disconnect the battery Guid...

Page 123: ...used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the passenger seat Preparatory work...

Page 124: ...ed out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109130 p 174 Tip Insert a new replacement fuse into the starter relay to have it available when ne...

Page 125: ...ed 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...

Page 126: ...Mount the protection cover Finishing work Mount the passenger seat p 79 14 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is l...

Page 127: ...it Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light turn signal alarm system optional Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10 A...

Page 128: ...or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 174 Fuse 75011088015 p 174 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the p...

Page 129: ...L SYSTEM 127 14 7 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine B00972 10 Main work Duke Remove screws 1 602577 10 Duke R Rem...

Page 130: ...ELECTRICAL SYSTEM 128 602578 11 Fold the headlight mask forward Disconnect plug 2 Set down the headlight mask 14 8 Refitting the headlight mask with the headlight 602578 10 Main work Plug in connector...

Page 131: ...ion the headlight mask Mount and tighten screws 2 Guideline Screw headlight EJOT 2 Nm 1 5 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Check that the lighting is functioning properly Finishing w...

Page 132: ...k with the headlight p 127 B00973 10 Main work Disconnect connector 1 Take off protection cap 2 B00974 10 Detach retaining clamp 3 Remove bulb 4 Position the new bulb in the headlight housing Headligh...

Page 133: ...setting p 133 14 10 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and k...

Page 134: ...9 5d p 174 Carefully position socket 2 with the bulb in the housing Mount cable sleeve 1 Finishing work Refit the headlight mask with the headlight p 128 Check the headlight setting p 133 14 11 Changi...

Page 135: ...and turn it counterclockwise first until it engages in the thread with a light jerk Tighten the screw slightly Check that the turn signal system is functioning properly 14 12 Checking the headlight se...

Page 136: ...34 14 13 Adjusting the headlight range Preparatory work Check the headlight setting p 133 B00976 10 Main work Adjust the beam distance of the headlight by turning screw 1 Guideline For a motorcycle wi...

Page 137: ...ture without causing any malfunctions 125 C 257 F 100167 10 Cooling takes place by means of the air stream and a radiator fan 4 which is controlled by a thermoswitch The lower the speed the less the c...

Page 138: ...ach of children Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface B01001 10 Main work Remove radiator cap 1 and plug 2 from the compensating tank Check...

Page 139: ...use of the loss Alternative 1 Coolant p 183 Alternative 2 Coolant mixed ready to use p 183 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system x p 140...

Page 140: ...he reach of children Condition The engine is cold The radiator is completely full Preparatory work Park the motorcycle on a horizontal surface B00982 10 Main work Check the coolant level in the compen...

Page 141: ...e engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant an...

Page 142: ...15 5 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rins...

Page 143: ...nt level in the compensating tank p 137 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there i...

Page 144: ...d with marking 2 Set the Map Select switch to Soft Set the adjusting wheel to position 1 Soft Homologated performance with very gentle response Set the Map Select switch to Advanced Set the adjusting...

Page 145: ...distance A 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 ba...

Page 146: ...ft procedure Mount and tighten the screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 222 602554 12 Duke R Loosen nut 1 holding the threaded rod 2 Info Nut 1 has a left handed thread Loose...

Page 147: ...16 TUNING THE ENGINE 145 Tighten nut 1 holding the threaded rod 2 Guideline Shift rods nut M6LH 6 Nm 4 4 lbf ft...

Page 148: ...tween the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 151 17 2 Changing the engine oil and filter cleaning the oil screens x...

Page 149: ...ainer under the engine Remove the oil drain plug 1 with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet B00988 10 Remove screws 2 Remove the...

Page 150: ...ain the engine oil Thoroughly clean the parts and sealing area B00991 10 Insert the oil filter Oil the O rings of the oil filter covers Mount oil filter covers 3 and 6 Mount and tighten the screws Gui...

Page 151: ...aling area B01002 10 Position the oil screen with the O rings Mount and tighten screw plug 8 with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft B00994 10 Position the oil screen with...

Page 152: ...ne oil SAE 10W 60 00062010035 p 184 Alternative engine oil Engine oil SAE 10W 50 p 184 Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and in...

Page 153: ...performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug 1 with the O ring Danger Danger of poisoning Exhaus...

Page 154: ...leaners 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 di...

Page 155: ...ns in the engine and on the brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 81 Treat bare metal parts except for brake discs and...

Page 156: ...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 w...

Page 157: ...le so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 152 Change the engine oil and filter clean the oil screens x p 146 Check the antifreez...

Page 158: ...ot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401059 01 Take the motorcycle off of the fron...

Page 159: ...utral Engine turns but does not start Operating error Carry out the start procedure p 52 Fuse 3 blown Change the fuses of individual power consumers p 124 Coupling of fuel hose connection not connecte...

Page 160: ...lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x N The idle indicator lamp does not light up when the transmission is in neutral Gear position...

Page 161: ...ake light and horn are not functional Fuse 5 blown Change the fuses of individual power consumers p 124 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p 12...

Page 162: ...ning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink...

Page 163: ...Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code of FI warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circ...

Page 164: ...Blink code of FI warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code of FI warning lamp MIL 39 FI warning lamp MI...

Page 165: ...Blink code of FI warning lamp MIL 82 FI warning lamp MIL flashes 8x long 2x short Error level condition Throttle position sensor circuit A input signal too high Throttle position sensor circuit A inpu...

Page 166: ...ort Error level condition Accelerator position sensor circuit B input signal too high Blink code of FI warning lamp MIL 87 FI warning lamp MIL flashes 8x long 7x short Error level condition Accelerato...

Page 167: ...amp MIL flashes 9x long 2x short Error level condition DBW throttle actuator control IC stuck open Blink code of FI warning lamp MIL 93 FI warning lamp MIL flashes 9x long 3x short Error level conditi...

Page 168: ...21 BLINK CODE 166 Blink code of FI warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level condition System voltage input signal too low System voltage input signal too high...

Page 169: ...ld 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 L ring 1 ta...

Page 170: ...ed 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 lb...

Page 171: ...k of camshaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 lbf ft S...

Page 172: ...lbf ft Loctite 243 Screw plug crankshaft clamp M8 20 Nm 14 8 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cylinder head screw M10 Tightening sequence Tighten diagonally beginning with th...

Page 173: ...e 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf f...

Page 174: ...Duke WP Suspension Up Side Down 4357 ROMA Fork Duke R WP Suspension 4357 ROTA SPLIT Shock absorber Duke WP Suspension 4618 with Pro Lever linkage Shock absorber Duke R WP Suspension 4618 with Pro Lev...

Page 175: ...ratio 16 40 Chain 5 8 x 1 4 520 X ring Steering head angle 63 5 Wheelbase Duke 1 447 15 mm 56 97 0 59 in Wheelbase Duke R 1 451 15 mm 57 13 0 59 in Seat height unloaded Duke 835 mm 32 87 in Seat heigh...

Page 176: ...25 25 A Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 22 5 Electrical system Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and...

Page 177: ...http www ktm com 22 7 Fork 22 7 1 Duke Fork part number 05 18 7L 19 Fork WP Suspension Up Side Down 4357 ROMA Spring rate Medium standard 6 0 N mm 34 3 lb in Fork length 816 mm 32 13 in Fork oil per...

Page 178: ...ndard 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 fl oz Fork oil SAE 4 48601166S1 p 185 22 8 Shock absorber 22 8 1 Duke...

Page 179: ...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 clicks Rebound damping Comfort 20 clicks St...

Page 180: ...crew headlight EJOT 2 Nm 1 5 lbf ft Screw headlight mask EJOT 1 Nm 0 7 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 l...

Page 181: ...w battery terminal M6 2 Nm 1 5 lbf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw chain sliding guard M6 10 Nm 7 4 lbf ft Loctite 243 Screw control unit holder M6 3 Nm 2 2 lbf f...

Page 182: ...t rear M8x30 25 Nm 18 4 lbf ft Loctite 243 Screw footrest bracket rear M8x50 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake disc M8 30 Nm 22 1 lbf ft Loctite 243...

Page 183: ...aining screws chassis M10 45 Nm 33 2 lbf ft Screw foot brake lever M10 25 Nm 18 4 lbf ft Screw handlebar support M10 20 Nm 14 8 lbf ft Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw subframe...

Page 184: ...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...

Page 185: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifre...

Page 186: ...sess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 189 SAE p 189 SAE 10W 50 Guidel...

Page 187: ...l that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Sho...

Page 188: ...aded 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...

Page 189: ...for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplie...

Page 190: ...r Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex...

Page 191: ...vice 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 wit...

Page 192: ...ar brake checking 100 Brake linings front brake checking 95 rear brake checking 103 Brake system 89 103 Brakes 58 Brakes applying 58 C Capacity coolant 172 engine oil 150 171 fuel 63 172 Chain checkin...

Page 193: ...stomer service 14 E Electric starter button 29 Emergency OFF switch 29 Engine running in 48 Engine characteristics setting 142 Engine number 22 Engine oil adding 151 changing 146 Engine oil level chec...

Page 194: ...checking 133 Horn button 27 I Ignition lock 30 Indicator lamps 32 Intended use 8 K Key number 21 L Light switch 27 Loading the vehicle 49 M Main fuse changing 121 Motorcycle cleaning 152 raising with...

Page 195: ...ice 13 Service schedule 64 65 Shift lever 43 basic position adjusting 143 basic position checking 143 Shifting 54 Shock absorber 66 compression damping general 68 compression damping high speed adjust...

Page 196: ...ition checking 113 Tool set 41 Transport 61 Troubleshooting 157 159 Turn signal bulb changing 132 Turn signal switch 28 Type label 20 U Use definition 8 V View of vehicle left front 16 right rear 18 W...

Page 197: ...3211953en 3211953en 09 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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