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KTM 690 DUKE R AUS/UK, Owner'S Manual, Page: 78 / 187

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KTM 690 DUKE R AUS/UK Owner'S Manual Download Page 78

SERVICE WORK ON THE CHASSIS

76

Guideline

Screw, chain sliding
guard

M6

10 Nm
(7.4 lbf ft)

Loctite

®

243™

10.15

Adjusting basic position of 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.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

100116-10

–

Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw

.

10.16

Checking/rectifying the fluid level of the hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.

Summary of Contents for 690 DUKE R AUS/UK

Page 1: ...OWNER S MANUAL 2011 690 Duke EU 690 Duke AUS UK 690 Duke R EU 690 Duke R AUS UK 690 Duke R JP Art no 3211664en...

Page 2: ......

Page 3: ...ght deviations resulting from continuing devel opment and design of our vehicles cannot however be completely excluded All specifications are non binding KTM Sportmotorcycle AG specifically reserves t...

Page 4: ...s is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance proce...

Page 5: ...ion instrument indicator lamps 25 Combination instrument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 28 Combination...

Page 6: ...Checking the chain tension 71 Adjusting the chain tension 72 Checking the chain rear sprocket and engine sprocket 74 Adjusting basic position of clutch lever 76 Checking rectifying the fluid level of...

Page 7: ...ngine characteristic 131 SERVICE WORK ON THE ENGINE 134 Checking the engine oil level 134 Changing the engine oil and filter cleaning the oil screens x 135 Draining the engine oil x 135 Removing the o...

Page 8: ...chnical understanding In the interest of your own safety have these jobs performed in an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using th...

Page 9: ...y muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit spe...

Page 10: ...mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is use...

Page 11: ...onflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you...

Page 12: ...the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this ow...

Page 13: ...11...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left example 601261 10...

Page 15: ...F VEHICLE 13 1 Combination instrument p 24 2 Rear mirror 3 Clutch lever p 19 4 Seat 5 Handrails p 35 6 Fork compression adjustment 7 Fuel taps p 33 8 Shift lever p 36 9 Engine number p 16 10 Side stan...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right example 601262 10...

Page 17: ...ch p 21 2 Turn signal switch p 21 2 Horn button p 22 3 Filler cap 4 Emergency OFF switch p 22 4 Electric starter button p 23 5 Hand brake lever p 19 6 Chassis number type label p 16 7 Passenger footre...

Page 18: ...06 01 The chassis number is stamped on the right of the steering head The type label is on the right of the frame behind the steering head 4 2 Engine number 700125 01 The engine number is stamped on t...

Page 19: ...79 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 4 4 Fork part number 700126 01 The fork part number is stamp...

Page 20: ...SERIAL NUMBERS 18 4 5 Shock absorber part number 700128 01 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring toward the rear...

Page 21: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 500018 01 The hand brake lever is fitted on the right side of the handlebar...

Page 22: ...t switch 500020 01 The light switch is fitted on the left side of the handlebar Possible states Low beam on Light switch is turned downwards In this position the low beam and tail light are switched o...

Page 23: ...switch 500021 10 The turn signal switch 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 signal s...

Page 24: ...perated in this position 5 8 Emergency OFF switch 500022 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition...

Page 25: ...eering lock 600825 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 no...

Page 26: ...ion buttons Tachometer Indicator lights Display 5 12 Combination instrument function buttons 400833 10 You can change the display mode with the MODE button Possible display modes are distance traveled...

Page 27: ...g state of the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle speed indicator lamp lights up green...

Page 28: ...ow 5 15 Combination instrument display 400836 01 When you switch on the ignition all display segments light up for one second as a function test 400881 01 LEnGth Following the display function test th...

Page 29: ...speed is shown in kilometers per hour km h or in miles per hour mph 5 17 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting...

Page 30: ...ode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 18 Combination instrument time 400838 11 The time is shown in area of the display Info...

Page 31: ...ton pressed simultaneously The time is set 5 20 Combination instrument display ODO 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is reta...

Page 32: ...ng TRIP 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...

Page 33: ...amp lights up in parallel to the TRIP F display 5 24 Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter t...

Page 34: ...ng Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc t...

Page 35: ...The fuel taps are located on the left right under the fuel tank Possible states Fuel supply closed The knurled screws are turned clockwise as far as possible The level cannot be compensated and no fu...

Page 36: ...at lock 700131 01 The seat lock is located to the right of the seat You can lock it with the ignition key 5 29 Owner s manual 500031 10 You can find the owner s manual in its protective case on the un...

Page 37: ...1 The tool set is located in the storage compartment under the seat 5 31 Handrails 700130 01 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on...

Page 38: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 5 33 Shift lever 70013...

Page 39: ...can be seen in the photograph The neutral or idle position is between the first and second gears 5 34 Foot brake lever 700136 01 Foot brake lever is located in front of the right footrest The rear br...

Page 40: ...lded up during motorcycle use The side stand is coupled with the safety electric starter system see the riding instructions Possible states Side stand folded out The vehicle can be supported on the si...

Page 41: ...hing 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...

Page 42: ...he service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of clutch lever p 76 Adjust the basic p...

Page 43: ...elmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manu...

Page 44: ...le handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that it...

Page 45: ...brake fluid level p 84 Check the front brake linings p 81 Check the rear brake linings p 87 Check the brake system function Check the coolant level p 125 Check the chain for dirt p 69 Check the chain...

Page 46: ...d safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service...

Page 47: ...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 wi...

Page 48: ...passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of dang...

Page 49: ...as usual before putting it into operation Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and...

Page 50: ...fuel consumption will be considerably lower Accelerate only up to a speed suitable for the road surface and weather conditions When traveling in bends do not shift and accelerate very carefully To shi...

Page 51: ...rning Danger of accidents Failure of brake system If the foot brake lever is not released the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot bra...

Page 52: ...hicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some vehicle components become very hot when the vehicle is ope...

Page 53: ...ways switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as i...

Page 54: ...terial damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system You...

Page 55: ...l fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 176 Close the filler cap p 33 400882 10 Press the SET button for two seconds The fuel level warning lamp switches o...

Page 56: ...eakage Check the rear brake fluid level p 84 Check the free travel of the foot brake lever p 82 Lubricate the linkage of the rear wheel suspension x Check that the shock absorber and fork are leak tig...

Page 57: ...set correctly Change the air filter Clean the air filter box x Check the fuel pressure x Check the CO adjustment with the KTM diagnostics tool x Check rectify the fluid level of the hydraulic clutch...

Page 58: ...SERVICE SCHEDULE 56 K10N Once after 1 000 km 621 4 mi K75A Every 7 500 km 4 660 mi or annually K150A Every 15 000 km 9 321 mi or every 2 years K300A Every 30 000 km 18 641 mi or every 4 years...

Page 59: ...the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9...

Page 60: ...yload 10 clicks Compression damping Duke R Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9...

Page 61: ...Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 4 Compression damping of the shock absorber The compression damping of the sho...

Page 62: ...ger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be gla...

Page 63: ...o Turn clockwise to increase damping turn counterclockwise to reduce damping 9 6 Adjusting the high speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressuriz...

Page 64: ...of turns corresponding to the shock absorber type Guideline Compression damping high speed Duke Comfort 2 0 turns Standard 1 5 turns Sport 1 0 turn Full payload 1 0 turn Compression damping high speed...

Page 65: ...op will be glad to help 700148 01 Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline...

Page 66: ...the handlebar to the straight ahead position Align the front wheel stand with the fork legs using the adapters Front wheel stand 61029055300 Info Always raise the rear of the motorcycle first Raise th...

Page 67: ...stand and screw into the swingarm on both sides Adapter 61029055110 Rear wheel stand 61029055100 Position the motorcycle upright align the stand and raise the motorcycle 10 4 Taking the motorcycle off...

Page 68: ...screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Info Carry out this action on both fork legs 10 6 Removing the seat 700131 01 Insert the igni...

Page 69: ...be inserted into the frame Push the locking pin into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click Remove the ignition key from the sea...

Page 70: ...and move it backwards Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat ing tank see illustration Place a cloth between the compensating tank and the spoiler...

Page 71: ...uideline Screw fuel tank bracket M8 15 Nm 11 1 lbf ft Check the routing of the fuel hoses Mount the seat p 67 10 10 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If the chain...

Page 72: ...l hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the cha...

Page 73: ...ion 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 if nece...

Page 74: ...sprocket 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 br...

Page 75: ...marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check this setting at different chain positions Tighten nuts Make s...

Page 76: ...et 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 s...

Page 77: ...ce at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket shou...

Page 78: ...erclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adju...

Page 79: ...zontal position 100194 10 Check the fluid level The fuel level must be between MIN and MAX If the level of the coolant does not meet specifications Remove the screw cap with the membrane Correct the f...

Page 80: ...Checking the brake discs Warning Danger of accidents 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 10...

Page 81: ...rk 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 accident...

Page 82: ...he eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and re...

Page 83: ...mark Brake fluid DOT 4 DOT 5 1 p 173 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 11 5 Checking the front bra...

Page 84: ...or minimum thickness Minimum thickness 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 wear or...

Page 85: ...cidents 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 free travel on foot brak...

Page 86: ...ount and tighten screw Guideline Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Reconnect spring 11 8 Checking rear brake fluid level Warning Danger of accidents F...

Page 87: ...brake fluid x Warning Danger of accidents 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 th...

Page 88: ...s stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between...

Page 89: ...scs 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 rendered unserviceable Check the...

Page 90: ...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 700156 10 Loosen screws and Unscrew screw about 6 turns and press your hand on...

Page 91: ...thread of the wheel spindle and screw Long life grease p 178 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24...

Page 92: ...wn hard on the fork several times to align the fork legs Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Take the motorcycle off of the rear wheel stand p 65 12 3 Removing rear whe...

Page 93: ...out of the swingarm Info Do not operate the foot brake when the rear wheel is removed 12 4 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on t...

Page 94: ...e brake caliper on the brake disc 100147 10 Push the brake caliper support and the swingarm into the fixing location Lay the chain on the rear sprocket and mount the wheel spindle Info Mount the left...

Page 95: ...90 100148 10 Check bearing If the bearing is damaged or worn Replace the bearings x Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn C...

Page 96: ...vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed in...

Page 97: ...f the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture...

Page 98: ...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...

Page 99: ...with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Flush with copious amounts of water in case of skin contact If battery acid com...

Page 100: ...isconnect plug in connector Remove cover 700165 10 Pull battery up and out of the battery rack Take the battery out of the frame toward the right Info Never operate the motorcycle with a discharged ba...

Page 101: ...3 2 Installing the battery x 700165 11 Push battery from the right into the frame Position the battery in the battery rack Info The battery terminals must be at the front 700164 11 Position cover Conn...

Page 102: ...11 Secure the cover with rubber band Connect positive cable Position positive terminal cover 700162 11 Secure the cover with rubber band Attach the minus cable Position the fuel tank p 68 Mount the s...

Page 103: ...ontact If battery acid comes into contact with the eyes flush the eyes with water for at least 15 minutes and consult a physician Warning Environmental hazard Battery parts and acid are harmful to the...

Page 104: ...ugh 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 s...

Page 105: ...y with a maximum of 10 of the capacity specified on the bat tery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must n...

Page 106: ...mers and switch off the engine Remove the seat p 66 Reinstall the fuel tank p 67 700166 01 Remove protective cover 700167 01 Remove a defective main fuse with needle nose pliers Install a new main fus...

Page 107: ...g the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and the engine Remove the seat p...

Page 108: ...king light tail light license plate lamp Fuse 8 10 A for auxiliary equipment accessories connected with ignition switch Fuse 9 10 A for auxiliary equipment permanent positive Fuse 10 not used Fuse SPA...

Page 109: ...e fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Mount the seat p 67 13 6 Removing headlight mask with headlight 700169 10 Re...

Page 110: ...ELECTRICAL SYSTEM 108 700171 01 Disconnect plug in connector 700172 10 Remove the screw fitting on both sides Place the headlight mask to one side...

Page 111: ...13 7 Installing the headlight mask with the headlight 700172 11 Position the headlight mask Mount and tighten screws on both sides Guideline Screw headlight mask M6 5 Nm 3 7 lbf ft 700171 01 Connect...

Page 112: ...headlight mask M6 5 Nm 3 7 lbf ft Check the lighting function 13 8 Changing the low beam bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be depos...

Page 113: ...ELECTRICAL SYSTEM 111 700169 10 Remove screws 700170 10 Fold the headlight mask forward...

Page 114: ...and remove it Detach the connector Position the new headlight bulb in the headlight housing Connect the connector Low beam high beam HB3 socket P20d p 162 Info Insert the headlight bulb so that the ba...

Page 115: ...bf ft Check lighting function 13 9 Changing the high beam bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the...

Page 116: ...10 Turn headlight lamp counterclockwise and remove it Detach the connector Position the new headlight bulb in the headlight housing Connect the connector Low beam high beam HB3 socket P20d p 162 Info...

Page 117: ...headlight mask M6 5 Nm 3 7 lbf ft Check lighting function 13 10 Changing the parking light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be depo...

Page 118: ...remove it 700176 01 Pull the parking light bulb out of the holder Insert a new parking light bulb in the holder Parking light W5W socket W2 1x9 5d p 162 Position the bulb holder and turn it clockwise...

Page 119: ...gnal RY10W socket BAU15s p 162 Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly Check that the turn signal system is...

Page 120: ...t on a horizontal surface in front of a light wall and make a mark at the height of the center of the high beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2...

Page 121: ...01 Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark the mark is created in Checking headlight...

Page 122: ...ition the headlight mask Mount and tighten screws Guideline Screw headlight mask M6 5 Nm 3 7 lbf ft 13 15 Adjusting the light range of the high beam headlight Check the high beam headlight adjustment...

Page 123: ...lower mark the mark is created in Checking headlight adjustment Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a heavy payload you...

Page 124: ...without causing any malfunctions 125 C 257 F 100167 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooling...

Page 125: ...t out of the reach of children Condition Engine is cold Remove the seat p 66 Reinstall the fuel tank p 67 700181 10 Stand the motorcycle upright on a horizontal surface Remove the cap of the compensat...

Page 126: ...ck the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1...

Page 127: ...skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im...

Page 128: ...If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system x p 127 Mount the radiator cap Position the fuel tank p 68 Mount the seat p 67 14 4 Draining the...

Page 129: ...able container under the engine Remove screw Take off the radiator cap Completely drain the coolant Mount screw with a new seal ring and tighten it Guideline Plug drain hole of water pump Duke M10x1 1...

Page 130: ...it emerges without bubbles at the vent hole and then mount and tighten the bleeder screw immediately Alternative 1 Coolant p 173 Alternative 2 Coolant mixed ready to use p 173 Fill the radiator comple...

Page 131: ...e 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 700181 11 Stop the engine and allow it to coo...

Page 132: ...y in the throttle cable x p 131 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is su...

Page 133: ...rive to the basic position Loosen counter nut Set the play in the throttle cable by turning the adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten counter nut 15 3 Adjusting the...

Page 134: ...Select switch to Soft Set the adjusting wheel to position 1 Soft reduced homologated peak performance for better driveability Set the Map Select switch to Advanced Set the adjusting wheel to position...

Page 135: ...TUNING THE ENGINE 133 700196 11 Position the Map Select switch in the holder Push the Map Select switch with the holder upward onto the retaining bracket...

Page 136: ...s at operating temperature Stand the motorcycle upright on a horizontal surface 700185 01 Check the engine oil level Info After switching off the engine wait one minute before checking the level The e...

Page 137: ...anger 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 Warni...

Page 138: ...Mount the oil drain plug with the magnet and seal ring and tighten it Guideline Oil drain plug with magnet Duke M12x1 5 20 Nm 14 8 lbf ft Oil drain plug with magnet Duke R M12x1 5 20 Nm 14 8 lbf ft 16...

Page 139: ...tions Place a suitable container under the engine 700188 01 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 7...

Page 140: ...unt and tighten the screws Guideline Screw oil filter cover Duke M5 6 Nm 4 4 lbf ft Screw oil filter cover Duke R M5 6 Nm 4 4 lbf ft 16 6 Cleaning the oil screens x Warning Danger of scalding Engine o...

Page 141: ...uel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Place a suitable container under the engine 700191 01 Remove plug with oil screen and the O rings 700192 01 R...

Page 142: ...ft Plug oil screen Duke R M20x1 5 15 Nm 11 1 lbf ft 700194 01 Position oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen Duke M20x1 5 15 Nm 11 1 lbf ft...

Page 143: ...ing Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do...

Page 144: ...engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousn...

Page 145: ...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...

Page 146: ...allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 69 Treat bare metal parts except for brake discs and exh...

Page 147: ...d water Warm water enhances the corrosive effects of salt 401060 01 Clean the motorcycle p 143 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based...

Page 148: ...le so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 143 Change the engine oil and filter clean the oil screens x p 135 Check the antifreez...

Page 149: ...warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Putting into operation after storage 401059 01 Take the motorcycle off of the fr...

Page 150: ...s not start Operating error Carry out the start procedure p 44 Fuse 4 blown Change the fuses of individual power consumers p 105 Coupling of fuel hose connection not connected Reconnect coupling of fu...

Page 151: ...lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine dies during the journey Lack of fuel Refuel p 51 Fuse 1 2 or 4 blown Change the fuses...

Page 152: ...parked Recharge the battery x p 101 Battery is not charged by alternator Check the charging voltage x Check the quiescent current x Combination instrument shows nothing in the display Fuse 1 blown Ch...

Page 153: ...L 08 FI warning lamp MIL flashes briefly 8x Error level condition Throttle grip sensor input signal too low Throttle grip sensor input signal too high Blink code FI of warning lamp MIL 09 FI warning l...

Page 154: ...re sensor input signal too low Ambient air pressure sensor input signal too high Blink code FI of warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor...

Page 155: ...MIL flashes 3x long 7x short Error level condition Ignition coil cylinder 1 circuit fault Blink code FI of warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error level condition Fuel p...

Page 156: ...short Error level condition EPT motor drive relay permission signal fault Blink code FI of warning lamp MIL 60 FI warning lamp MIL flashes 6x long Error level condition Motor drive circuit fault Blin...

Page 157: ...BLINK CODE 155 Blink code FI of warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condition Motor drive voltage internal circuit fault...

Page 158: ...n Valve diameter exhaust 34 mm 1 34 in Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Duke Bronze bush Piston pin b...

Page 159: ...12 V 224 W Spark plug NGK LKAR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor...

Page 160: ...l filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw alterna...

Page 161: ...rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 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 pu...

Page 162: ...net M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rot...

Page 163: ...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 mm 9 4...

Page 164: ...Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fu...

Page 165: ...70 ZR 17 M C 58W TL Michelin Pilot Power 160 60 ZR 17 M C 69W TL Michelin Pilot Power Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel ta...

Page 166: ...Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer s 352 mm 13 86 in Spring rate Mediu...

Page 167: ...rt 10 clicks Full payload 10 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring length with preload spacer s 352 mm 13 86 in Spring rate Medium s...

Page 168: ...0 turns Standard 1 5 turns Sport 1 0 turn Full payload 1 0 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 cl...

Page 169: ...14 8 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 175 25 2 Duke R Shock absorber part number 15 18 7J 46 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression dampi...

Page 170: ...12 mm 0 47 in Sport 12 mm 0 47 in Full payload 15 mm 0 59 in Spring rate Medium standard 70 N mm 400 lb in Hard 75 N mm 428 lb in Spring length 185 mm 7 28 in Gas pressure 10 bar 145 psi Static sag 25...

Page 171: ...f ft Screw pressure regulator M5 4 Nm 3 lbf ft Screw seat lock M5 3 Nm 2 2 lbf ft Loctite 222 Screw side cover M5 2 Nm 1 5 lbf ft Screw starter cable on starter M5 3 Nm 2 2 lbf ft Lower radiator brack...

Page 172: ...tite 243 Screw SLS valve M6 6 Nm 4 4 lbf ft Screw voltage regulator M6 8 Nm 5 9 lbf ft Nut manifold on cylinder head M8 25 Nm 18 4 lbf ft Copper paste Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loct...

Page 173: ...e carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 45 Nm 33 2 lbf ft Loctite...

Page 174: ...swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw steering head M20x1 5 12 Nm 8 9 lbf ft Adjusting ring of swingarm bearing M24x1 5 25 Nm 18 4 lbf ft Screw front wheel spindle M24x1 5 40 Nm 29 5 lbf ft...

Page 175: ...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 antifree...

Page 176: ...e corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 179 SAE p 179 SAE 10W 50 G...

Page 177: ...ic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM r...

Page 178: ...SUBSTANCES 176 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 179: ...or 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 Supplier...

Page 180: ...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 p...

Page 181: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with...

Page 182: ...checking 87 Brakes 49 Braking 49 C Chain checking 74 cleaning 69 dirt checking for 69 Chain tension adjusting 72 checking 71 Chassis number 16 Clutch checking correcting fluid level 76 Clutch lever 19...

Page 183: ...aining 135 refilling 140 Engine oil level checking 134 Engine sprocket checking 74 Environment 9 F Filler cap closing 33 opening 32 Filling up fuel 51 Foot brake lever 37 basic position adjusting 83 f...

Page 184: ...on lock 23 Indicator lamps 25 K Key number 17 L Light switch 20 Loading the vehicle 41 Low beam bulb changing 110 M Main fuse changing 103 Motorcycle cleaning 143 raising with the front wheel stand 64...

Page 185: ...Service schedule 54 56 Shift lever 36 Shifting 45 Shock absorber 57 compression damping general 59 compression damping high speed adjusting 61 compression damping low speed adjusting 60 rebound dampin...

Page 186: ...NDEX 184 Transport 8 Troubleshooting 148 150 Turn signal bulb changing 116 Turn signal switch 21 Type label 16 U Use definition 7 V View of vehicle front left 12 right rear 14 W Warranty 7 Work rules...

Page 187: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2010 Photo Mitterbauer 3211664en 3211664en...

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