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KTM 690 Duke R, Owner'S Manual, Page: 85 / 193

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KTM 690 Duke R Owner'S Manual Download Page 85

11

SERVICE WORK ON THE CHASSIS

83

11.13

Checking the chain, rear sprocket and engine sprocket

100132-10

–

Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:

–

Change the power set.

Info

The engine sprocket, rear sprocket and chain should always be replaced
together.

Summary of Contents for 690 Duke R

Page 1: ...OWNER S MANUAL 2015 690 Duke EU 690 Duke CN 690 Duke R EU 690 Duke R AU 690 Duke R MY Art no 3213272en...

Page 2: ......

Page 3: ...completely All specifications are non binding KTM Motorrad AG specifically reserves the right to modify or delete technical specifications prices col ors forms materials services designs equipment et...

Page 4: ...1 According 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 T V Management Service KT...

Page 5: ...ype label 20 5 3 Key number 21 5 4 Engine number 22 5 5 Fork part number 22 5 6 Shock absorber part number 23 6 CONTROLS 24 6 1 Clutch lever 24 6 2 Hand brake lever 24 6 3 Throttle grip 25 6 4 Horn bu...

Page 6: ...ing of the shock absorber Duke R 64 10 5 Adjusting the high speed compression damping of the shock absorber Duke R 64 10 6 Adjusting the low speed compression damping of the shock absorber Duke R 65 1...

Page 7: ...11 13 7 Checking the tire pressure 113 14 ELECTRICAL SYSTEM 114 14 1 Removing the battery 114 14 2 Installing the battery 115 14 3 Recharging the battery 116 14 4 Changing the main fuse 119 14 5 Chang...

Page 8: ...NG 155 21 FLASH CODE 158 22 TECHNICAL DATA 165 22 1 engine 165 22 2 Engine tightening torques 166 22 3 Capacities 169 22 3 1 Engine oil 169 22 3 2 Coolant 170 22 3 3 Fuel 170 22 4 Chassis 170 22 5 Ele...

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: ...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 pro...

Page 12: ...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...

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: ...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...

Page 16: ...erve 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 component...

Page 17: ...15...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example M00653 10...

Page 19: ...4 VIEW OF VEHICLE 17 1 Clutch lever p 24 2 Seat 3 Passenger seat 4 Handrails p 41 5 Seat lock p 40 6 Engine number p 22 7 Shift lever p 42 8 Side stand p 43...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example M00654 10...

Page 21: ...27 2 Turn signal switch p 27 2 Horn button p 26 3 Filler cap 4 Ignition steering lock p 29 5 Emergency OFF switch p 28 5 Electric starter button p 28 6 Hand brake lever p 24 7 Chassis number p 20 8 F...

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 402294 10 The type label is located on the right side of the frame...

Page 23: ...90 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 Ke...

Page 24: ...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 o...

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

Page 26: ...M00656 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 602570 10 Duke The hand brake lever is fitted on th...

Page 27: ...10 Duke R The hand brake lever 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 is fitted on the right s...

Page 28: ...ssed The horn is operated in this position 6 5 Light switch M00656 11 The light switch is fitted on the left side of the handlebar Possible states Low beam on Light switch is turned downwards In this...

Page 29: ...6 7 Turn signal switch M00655 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...

Page 30: ...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 31: ...y 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...

Page 32: ...IP 1 trip master 2 TRIP 2 and gear display GEAr Press the SET button 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 6 11...

Page 33: ...high 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 rese...

Page 34: ...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 35: ...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 accord...

Page 36: ...l 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 of the display Info After reco...

Page 37: ...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 38: ...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 39: ...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 40: ...always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if...

Page 41: ...tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap 6 13 Closing the filler cap M00658 01 Fold down the filler cap Turn the ignition key 90 clockwise Push down the fille...

Page 42: ...NTROLS 40 6 14 Seat lock B00928 10 The seat lock 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 is located under the passenger s...

Page 43: ...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 fol...

Page 44: ...2 6 18 Shift lever 401950 10 The shift lever is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and...

Page 45: ...cle The side stand is used for 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...

Page 46: ...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 47: ...your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 85 Adjust the basic position of the hand brake lever p 88 Adj...

Page 48: ...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 49: ...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 50: ...vel p 98 Check the front brake linings p 93 Check the rear brake linings p 100 Check the brake system function Check the coolant level in the compensating tank p 135 Check the chain for dirt p 77 Chec...

Page 51: ...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 52: ...equipped 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 s...

Page 53: ...lock up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffi...

Page 54: ...the tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational...

Page 55: ...release the clutch lever and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used...

Page 56: ...the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents R...

Page 57: ...arning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface When braking...

Page 58: ...ot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may r...

Page 59: ...nd forward with your 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...

Page 60: ...the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If con...

Page 61: ...off the engine Open the filler cap p 38 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 182 C...

Page 62: ...heck the rear brake linings p 100 Check the brake discs p 89 Check the brake lines for damage and leakage Check the rear brake fluid level p 98 Check the free travel of the foot brake lever p 94 Check...

Page 63: ...ange the air filter Clean the air filter box Check the fuel pressure Check the CO adjustment with the KTM diagnostics tool Check rectify the fluid level of the hydraulic clutch p 86 Check the screws a...

Page 64: ...t change 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...

Page 65: ...rk Duke R Info The hydraulic rebound damping determines the fork suspension behavior 602572 10 Turn the red adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of th...

Page 66: ...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 more...

Page 67: ...eline 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 com...

Page 68: ...ber 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 dam...

Page 69: ...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 t...

Page 70: ...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 Hook wrench T106S Turn adjusting ring to adju...

Page 71: ...er Remove the motorcycle from the work stand Install the footrest bracket 10 9 Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides C00329 10...

Page 72: ...THE CHASSIS 70 C00330 10 Remove screws C00331 01 Adjust the footrest bracket to the desired position C00330 10 Mount and tighten screws Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loc...

Page 73: ...10 TUNING THE CHASSIS 71 C00332 01 Mount the rider footrest with the spring and pin C00329 10 Mount lock ring...

Page 74: ...uke R 101968 10 Remove screw along with the foot brake lever stub Position foot brake lever stub along with screw in the desired drilled hole Guideline Standard Front drilled hole Tighten the screw Gu...

Page 75: ...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 76: ...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 73 602543 01...

Page 77: ...l 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 ig...

Page 78: ...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 79: ...ransporting a passenger Do not ride with a passenger 602560 10 Hook catches of the passenger seat cover onto the storage compartment lower the rear and simultaneously push forward Press down the passe...

Page 80: ...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 81: ...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 the transmission t...

Page 82: ...chain upwards near 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 pos...

Page 83: ...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 the transmission to break in extreme case...

Page 84: ...the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain we...

Page 85: ...ain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rea...

Page 86: ...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 the distance is greater than the sp...

Page 87: ...rd M6 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 Tu...

Page 88: ...luid B00944 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 1...

Page 89: ...e been approved 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...

Page 90: ...wheels 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...

Page 91: ...dents 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 re...

Page 92: ...hat 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 o...

Page 93: ...ake 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 irritation...

Page 94: ...n brake 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 93 B00948 10 Main work Duke Move the brake...

Page 95: ...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 author...

Page 96: ...e 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...

Page 97: ...c position of the 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 f...

Page 98: ...er 3 5 mm 0 12 0 2 in Hold screw and tighten nut Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Hold ball joint and tighten nut Guideline Mount and tighten screw Guideline Screw ball joint of pu...

Page 99: ...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 brake lever 3 5 mm 0 12 0 2 in Hold screw and...

Page 100: ...uid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help M00663 10 Stand the vehicle upright Check the brake fluid lev...

Page 101: ...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 damage Oil g...

Page 102: ...11 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad...

Page 103: ...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 brake linings for damage and cracking If there is...

Page 104: ...he 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 105: ...front wheel and remove the wheel spindle Take the front wheel out of the fork 13 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake d...

Page 106: ...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 bu...

Page 107: ...not tighten yet Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the acti vated position Th...

Page 108: ...The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 13 3 Removing the rear wheel Preparatory work Raise the motorcycle with the rear wheel stand p 73 M00665 10 Main...

Page 109: ...em 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 disc and rim Warning Danger of acciden...

Page 110: ...g the rear wheel always operate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers p 110 602566 10 Check the wheel bearing for damage and wear If the wheel...

Page 111: ...correctly 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...

Page 112: ...the rear wheel p 106 602568 10 Main work Check bearing If the bearing is damaged or worn Replace the bearings Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear...

Page 113: ...ferent 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 accide...

Page 114: ...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 115: ...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 116: ...ttery 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...

Page 117: ...ry up and out of the battery holder 14 2 Installing the battery M00671 10 Main work Position the battery in the battery holder Battery CBTX9 BS p 171 The battery terminals face in the direction of tra...

Page 118: ...ith 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...

Page 119: ...fe 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 ve...

Page 120: ...ry 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 charg...

Page 121: ...re used 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 wo...

Page 122: ...burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 172 Tip Insert a new replacement fuse into the starter relay to have it available when n...

Page 123: ...located 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 S...

Page 124: ...t the protection cover Finishing work Mount the passenger seat p 76 14 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is locate...

Page 125: ...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 126: ...s or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 172 Fuse 75011088015 p 172 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the...

Page 127: ...CAL SYSTEM 125 14 7 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine M00677 10 Main work Duke Remove screws 602577 10 Duke R Rem...

Page 128: ...AL SYSTEM 126 602578 11 Fold the headlight mask forward Disconnect plug in connectors Remove the headlight mask 14 8 Refitting the headlight mask with the headlight 602578 10 Main work Connect plug in...

Page 129: ...ion the headlight mask Mount and tighten screws 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 wor...

Page 130: ...engine Remove the headlight mask with the headlight p 125 B00973 10 Main work Unplug connector Remove protection cap B00974 10 Detach retaining clamp Remove bulb Position the new bulb in the headligh...

Page 131: ...tting p 131 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 kee...

Page 132: ...9 5d p 172 Carefully position socket with the bulb in the housing Mount cable sleeve Finishing work Refit the headlight mask with the headlight p 126 Check the headlight setting p 131 14 11 Changing t...

Page 133: ...the screw 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 h...

Page 134: ...132 14 13 Adjusting the headlight range Preparatory work Check the headlight setting p 131 M00679 10 Main work Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle wit...

Page 135: ...re 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 cooli...

Page 136: ...reach of children Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface M00680 10 Main work Remove radiator cap and plug from the compensating tank Check...

Page 137: ...oss Coolant p 180 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system p 138 Mount radiator cap 15 3 Checking the coolant level in the compensating tan...

Page 138: ...ant out of reach of children Condition The engine is cold The radiator is completely full Preparatory work Park the motorcycle on a horizontal surface M00681 10 Main work Check the coolant level in th...

Page 139: ...not come 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 a...

Page 140: ...ap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children M00682 10 Remove radiator cap B00985 10 Rem...

Page 141: ...nt 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...

Page 142: ...sired number is aligned with marking 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 Advance...

Page 143: ...iding 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 sp...

Page 144: ...the shift procedure Mount and tighten the screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 602554 12 Duke R Loosen nut holding the threaded rod Info Nut has a left handed thread Loos...

Page 145: ...16 TUNING THE ENGINE 143 Tighten nut holding the threaded rod Guideline Shift rods nut M6LH 6 Nm 4 4 lbf ft...

Page 146: ...etween 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 149 17 2 Changing the engine oil and filter cleaning the oil screens...

Page 147: ...container under the engine Remove the oil drain plug with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet B00988 10 Remove screws Remove the...

Page 148: ...rain 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 and Mount and tighten the screws Guidel...

Page 149: ...aling area B01002 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 B00994 10 Position the oil screen with th...

Page 150: ...oil SAE 10W 60 00062010035 p 180 Alternative engine oil Engine oil SAE 10W 50 p 181 Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inha...

Page 151: ...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 with the O ring Danger Danger of poisoning Exhaust...

Page 152: ...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 153: ...d on the brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 78 Treat bare metal parts except for brake discs and exhaust system wit...

Page 154: ...Clean the motorcycle p 150 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...

Page 155: ...ueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 183 Refuel p 58 Clean the motorcycle p 150 Change the engine oil and filter clean the oil screens...

Page 156: ...ort time only Since the engine cannot 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...

Page 157: ...r to neutral Engine turns but does not start Operating error Carry out the start procedure p 49 Fuse 3 blown Change the fuses of individual power consumers p 122 The plug in connection of the fuel hos...

Page 158: ...ghts 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 sen...

Page 159: ...brake light and horn are not functional Fuse 5 blown Change the fuses of individual power consumers p 122 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p...

Page 160: ...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 161: ...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 162: ...ult 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 lam...

Page 163: ...ode 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 input signa...

Page 164: ...short 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 Accelera...

Page 165: ...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 condition CPU mutual surveillance error Blink code of FI warni...

Page 166: ...21 FLASH CODE 164 Blink code of FI warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level condition System voltage input voltage too low System voltage input signal too high...

Page 167: ...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 168: ...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 169: ...octite 243 Screw axial lock 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 cylinde...

Page 170: ...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 171: ...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 172: ...e Down 4357 Fork Duke R WP Suspension 4357 ROTA SPLIT Shock absorber Duke WP Suspension emulsion with Pro Lever linkage Shock absorber Duke R WP Suspension 4618 with Pro Lever deflector Suspension tra...

Page 173: ...ratio 16 40 Chain 5 8 x 1 4 520 X ring Steering head angle 63 5 Wheelbase 1 466 15 mm 57 72 0 59 in Seat height unloaded Duke 835 mm 32 87 in Seat height unloaded Duke R 865 mm 34 06 in Ground clearan...

Page 174: ...light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal Duke RY10W socket BAU15s 12 V 10 W Turn signal Duke R LED Brake tail light LED License plate lamp LED 22 6 Tir...

Page 175: ...Fork oil per fork leg 480 ml 16 23 fl oz Fork oil SAE 4 48601166S1 p 181 22 7 2 Duke R Fork part number 05 18 8M 11 Fork WP Suspension 4357 ROTA SPLIT Compression damping Comfort 17 clicks Standard 12...

Page 176: ...bsorber 22 8 1 Duke Shock absorber part number 01 18 7N 19 Shock absorber WP Suspension emulsion with Pro Lever linkage Spring preload Standard 4 clicks Static sag 20 mm 0 79 in Riding sag 45 mm 1 77...

Page 177: ...s Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Comfort 11 mm 0 43 in Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 11 mm 0 43 in Spring rate Soft 70 N mm 400 lb i...

Page 178: ...n starter motor M5 3 Nm 2 2 lbf ft Screw foot brake lever stub Duke M5 6 Nm 4 4 lbf ft Loctite 243 Screw fuel level sensor M5 3 Nm 2 2 lbf ft Screw fuel pump M5 4 Nm 3 lbf ft Screw heat guard Duke M5...

Page 179: ...rew lower radiator bracket M6 5 Nm 3 7 lbf ft Screw magnetic holder on side stand M6 5 Nm 3 7 lbf ft Loctite 243 Screw seat lock M6 10 Nm 7 4 lbf ft Loctite 222 Screw tail light cover M6 8 Nm 5 9 lbf...

Page 180: ...lbf ft Screw handrail M8x30 Countersunk screw 18 Nm 13 3 lbf ft Loctite 243 Screw handrail cover M8x20 18 Nm 13 3 lbf ft Loctite 243 Screw ignition lock tamper proof screw M8 Loctite 243 Screw license...

Page 181: ...9 lbf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Screw top shock absorber M10x1 25 50 Nm 36 9 lbf ft Loctite 243 Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Nut frame...

Page 182: ...UID 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 antifre...

Page 183: ...fication JASO T903 MA p 185 SAE p 185 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properti...

Page 184: ...ification SAE p 185 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties Super unleaded ROZ 95 RO...

Page 185: ...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...

Page 186: ...ex 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 Recommend...

Page 187: ...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 188: ...e linings front brake checking 93 rear brake checking 100 Brake system 87 101 Brakes 54 Brakes applying 54 C Capacity coolant 170 engine oil 148 169 fuel 59 170 Chain checking 83 cleaning 78 dirt chec...

Page 189: ...starter button 28 Emergency OFF switch 28 Engine running in 45 Engine characteristics setting 140 Engine number 22 Engine oil adding 149 changing 144 Engine oil level checking 144 Engine sprocket chec...

Page 190: ...ht setting adjusting 132 checking 131 Horn button 26 I Ignition lock 29 Indicator lamps 31 Intended use 8 K Key number 21 L Light switch 26 Loading the vehicle 46 M Main fuse changing 119 Motorcycle c...

Page 191: ...10 Seat lock 40 Service 13 Service schedule 60 61 Shift lever 42 basic position adjusting 141 basic position checking 141 Shifting 51 Shock absorber 62 compression damping general 64 compression damp...

Page 192: ...Tire condition checking 111 Tool set 40 Transport 57 Troubleshooting 155 157 Turn signal bulb changing 130 Turn signal switch 27 Type label 20 U Use definition 8 V View of vehicle left front 16 right...

Page 193: ...3213272en 3213272en 10 2014 KTM Motorrad AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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