KTM 690 LC4 Owner'S Manual Download

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Cooling system

The water pump in the engine ensures a forced circulation of the cooling liquid. When the

engine is cold, the cooling liquid only circulates in the cylinders and cylinder heads. The

thermostat will open when the engine reaches approx. 70°C (158°F) and the cooling liquid

will also be pumped through the aluminum radiator

[1]

Cooling is by means of the air stream. The lower the speed, the lower the cooling effect.

Soiled cooling fins also impair the cooling effect.

If, for example, slow urban traffic or waiting at a traffic light cause little or no air to stream

through the radiator, the temperature of the cooling liquid will rise. The radiator fan

[2]

switches

on when the cooling liquid reaches a temperature of 102°C (216°F). Additional air is blown

through the radiator to prevent the cooling system from overheating.

The temperature indicator [3] will begin to blink and the red cooling liquid temperature warn-

ing lamp [4] will light up when the cooling liquid reaches approx. 115°C (239°F), having

exceeded the normal operating temperature. Possible causes:

– Slow riding with large loads at a higher air temperature:

If possible increase your running speed, so that more air can blow through the radiators.

Should the warning light still be on off after 1500 meters (1 mile), stop immediately,

switch off the engine and look for other possible causes.

– The cooling fan on the radiator is not working:

The cooling fan must be running, when the cooling liquid temperature is 115°C (239°F)

and the ignition is on. If the fan is not working, and there appears to be sufficient cool-

ing liquid, the only thing you can do is to drive on to your nearest authorized KTM work-

shop at the least possible engine load.

– Too little cooling liquid in the system:

Check whether any cooling liquid is leaking out (also on the bottom of the motorcycle).

Let the engine cool down and check the cooling liquid level in the radiator (see chapter

Checking the cooling liquid level in the radiator). Only continue to drive if there is enough

cooling liquid in the system. Contact an authorized KTM workshop to have the error elim-

inated. You will damage the engine if you continue to drive when the cooling liquid tem-

perature warning lamp is on.

– Excessive use of the clutch at slow speed.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Summary of Contents for 690 LC4

Page 1: ...690 LC4 SUPERMOTO PRESTIGE 690 LC4 SUPERMOTO KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at 01 2007 FOTO MITTERBAUER KTM Group Partner ART NR 3 211 147 EN OWNER S MANUAL 2007 ...

Page 2: ...ON FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is...

Page 3: ... the latest information available for this model series at the time it was printed Minor devia tions resulting from enhancements to the motorcycle design cannot be entirely precluded The Owner s Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold SERVICE Observance of the service maintenance and operating instructions for the engine and...

Page 4: ...with equivalent specifications must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own safety only use spare parts and accessories approved by KTM KTM shall not assume any liability for other products or consequential damage resulting from the use of such products ENVIRONMENT Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it...

Page 5: ... fork 690 Supermoto Prestige 18 Rebound damping of shock absorber 19 Damping action during compression of shock absorber 690 Supermoto Prest 19 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 20 Instructions for initial operation 20 Running in the LC4 engine 20 Accessories and payload 21 DRIVING INSTRUCTIONS 22 Check the following before each start 22 Starting the engine 24 Starting off 25 S...

Page 6: ...placing the flasher bulbs 57 Adjusting the headlight range 57 Cooling system 58 Checking the cooling liquid level in the compensating tank 59 Checking the cooling liquid level in the radiator 60 Coolant drain plug 60 Bleeding the cooling system 61 Checking the oil level of the hydraulic clutch 690 Supermoto 62 Changing the original position of the clutch lever 62 Checking the oil level of the hydr...

Page 7: ...ad tube Enter this num ber in the field on page no 1 The type label is located next to the chassis number Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 SERIAL NUMBER LOCATIONS 6 ...

Page 8: ... The hand brake lever 3 is mounted on the right side of the handlebar The basic position of the handbrake lever can be changed in 4 or 5 steps see Maintenance work on chassis and engine OPERATION INSTRUMENTS 7 Clutch lever 690 Supermoto Prestige The clutch lever 2 is fitted on the left hand side of the handle bar The adjusting screw B is used to change the original position of the clutch lever see...

Page 9: ... MODE 1 Briefly press the MODE button to go to the next display mode The available display modes are distance traveled ODO trip master 1 TRIP 1 and trip master 2 TRIP 2 The speed cooling liquid temperature and time are always displayed SET 2 Press the SET button to reset trip master 1 or 2 to 0 The 3rd button is not programmed Combined instrument display TEST When you switch on the ignition all of...

Page 10: ... CLOCK display The clock must be set if the battery was disconnected or if the fuse 2 was blown SETTING THE CLOCK Switch on the ignition and select the ODO mode Press and hold the MODE button while you press the SET button more than 1 second The time will start to blink Use the MODE button to set the hours Use the SET button to set the minutes Then press the MODE and SET buttons simultaneously ODO...

Page 11: ...set the trip meter 2 to zero switch on the ignition select the TRIP 2 display mode and press the SET button more than 2 seconds Press the MODE button to go to the next display mode TRIP F 3 When the fuel level reaches the reserve mark the display will automatically switch to TRIP F and begin to count no matter which display mode was active before At the same time the fuel warning lamp will light u...

Page 12: ...s shown in 12 bars The more bars that light up the hotter the cooling liquid When the upper bar lights up 115 C 239 F all of the bars will start to blink and the red warning lamp 2 will light up Possible causes for an increase in temperature causing the red warning light for the cool ing liquid temperature to light up Driving too slowly and driving with a heavy load at high air temperatures Not en...

Page 13: ... orange warning lamp will light up when the fuel level has reached the reserve mark At the same time the display will automatically change to TRIP F see TRIP F The orange warning lamp fuel injection briefly lights up when the ignition is switched on It will go out when the gasoline pressure is high enough If this warning lamp lights up while driving a component in the injection system is defective...

Page 14: ...ress it into the lock Turn the handlebar to the left then turn the ignition key to the left The ignition key can be withdrawn in position and Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam High beam light Low beam light The light signal high beam is actuated with button 2 The indicator switch 3 returns to central position after actuation Press flasher switch towar...

Page 15: ...3 can be locked and is provided with a fuel evaporation control system To open the cap insert the ignition key turn it 90 counterclockwise then lift off the filler cap To close the tank insert the filler cap turn the ignition key 90 clockwise and take out the key OPERATION INSTRUMENTS 14 Fuel taps 2 fuel taps 4 are mounted on the fuel tank that must be open when the motorcycle is running The level...

Page 16: ...sliding it towards the front Both noses 4 should fit into the frame Insert the catch bolts 5 in the lock housing and push the seat down in the back until you hear the catch bolts snap into place Check whether the seat is correctly mounted If not correctly mounted the seat can slip while you are driving and cause you to lose con trol of your motorcycle OPERATION INSTRUMENTS 15 Grips The grips 1 are...

Page 17: ... protective cover included in the scope of supply and fasten it under the seat see photo Tool set The tool set 1 is located in the storage compartment under the seat Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear ...

Page 18: ...nd Make sure it is standing securely on a firm surface The side stand is linked to the safety start system follow the driving instructions Foot brake pedal The foot brake pedal 2 is located in front of the right footrest Its basic position can be adjusted to your seat position see maintenance work Footrests The passenger footrests 3 fold up ...

Page 19: ... 1 are located on the fork leg axle passage More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of fork The fork s damping action during rebound travel rebound damping can also be adjusted This allows you adjust the damping behavior to match your driving style and the payload The adjusting screws 2 are located on the upper end of the fork legs More inf...

Page 20: ...rber and not to the motorcycle s driving speed The adjusting screw 1 for the low speed range can be adjusted with a screwdriver The adjusting screw 2 for the high speed range can be adjusted with a 15 mm socket wrench More information is provided in the chapter Adjusting the fork and shock absorber Rebound damping of shock absorber The shock absorber s damping action during rebound travel rebound ...

Page 21: ... sections are properly roughened Tires will not display their full grip char acteristics until they are properly run in Motorcycles are sensitive to changes in the weight distribution Read the section on Accessories and payload when car rying luggage Pay attention to running in procedure Running in the LC4 engine Even finely machined surfaces of engine parts have rougher surfaces than parts that s...

Page 22: ...or cycle if passenger footrests are mounted Never leave your motorcycle without super vision if the engine is running Accessories and payload Accessory parts and baggage can signifi cantly decrease a motorcycle s driving stabil ity Please observe the following warnings Never drive faster than 130 kph 80 mph if you have mounted accessory parts on your motorcycle Accessory parts can sig nificantly i...

Page 23: ...heck for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 4 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake f...

Page 24: ...to engine damage 9 BAGGAGE PAYLOAD Never exceed the maximum total weight 350 kg 773 lbs and the motorcycle s wheel loads The maximum total weight is comprised of the motorcycle in a running condition and refueled 164 kg 362 lbs the baggage and accessories the driver and passenger with protective gear and helmet Adapt the tire air pressure and the damping properties of the fork and shock absorber t...

Page 25: ...aust fumes are poison ous and can cause loss of consciousness and death Always provide adequate ventila tion while the engine is running Never operate the motorcycle with a run down battery or without the battery This can damage the electronic components or safety equipment in either caseand the motorcy cle will no longer be roadworthy If you accelerate while starting the engine management will no...

Page 26: ...ch lever go again and carefully open throttle Do not shift gears and accelerate carefully in curves Only accelerate to the extent that road and weather conditions allow Be especially care ful when you accelerate in curves Abrupt opening of the throttle can cause the motor cycle to go out of control and also increases fuel consumption By shifting down use the brakes if neces sary and close throttle...

Page 27: ...l in the radiator not only in the compensating tank CAUTION SCALDING HAZARD Do not drive on until there is sufficient liquid in the coling system In the event that while riding on your motorcycle you notice any unusual oper ation related noise stop immediately turn the engine off and contact an author ized KTM dealer Braking Close throttle and apply the hand and foot brakes at the same time Carefu...

Page 28: ...The engine radiators exhaust exhaust system brake discs and shock absorbers can become very hot Do not touch any of these parts after operating the motorcycle and take care to park it where pedestrians are not likely to touch it and get burned Never park your motorcycle in places where there exist fire hazards due to dry grass or other easily flammable materials Always take out the ignition key wh...

Page 29: ...fueling it will take approx 3 minutes for the fuel warning lamp 1 to switch off and for TRIP F to automatically reset to 0 and return to the previous display mode Press the SET key 2 for 2 seconds to immediately turn off the fuel warning lamp Gasoline is highly flammable and poisonous Extreme caution should be used when han dling gasoline Do not refuel the motorcycle near open flames or burning ci...

Page 30: ...29 ...

Page 31: ... a status check of neutral clutch 2nd 3rd gear and side stand switch using the KTM diagnosis tool z z z Make sure the fuel hose SAS hoses and vent hoses are run correctly and check for damage z z z Replace the O ring on the fuel hose connection and check for leaks z z z Check the wiring harness on the throttle body for proper installation and damage z z ADD ON PARTS Check cooling system for leaks ...

Page 32: ...y off switch z z z Make sure all bolts and nuts are tight z z z BRAKES Check brake fluid level lining thickness and brake discs z z z Change brake fluid z Check brake lines for damage and leaks z z z Check adjust smooth operation free travel of handbrake footbrake levers z z z Check bolts of brake system for tight fit z z z CHASSIS Check shock absorber and fork for leaks and proper operation z z z...

Page 33: ...ELS Check rim joint z z z Check tire condition and inflation pressure z z z Check chain sprockets and chain guides for wear force fit and tension z z z Check bolts on pinion and chain sprocket for locking devices and a tight fit z z z Lubricate chain z z z Check wheel bearings and jerk damper for play z z 690 SUPERMOTO 690 SUPERMOTO PRESTIGE 2007 ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEP...

Page 34: ...Check horn for proper operation z Lubricate actuating cables and nipples z Bleed fork legs z Clean chain z Lubricate chain z z Check chain tension z Check tire pressure and wear z Check coolant level z Check fuel lines for leaks z Check all control elements for smooth running z Grease the hand brake lever and clutch lever z Check brake performance z z Treat exposed metal components except for the ...

Page 35: ...emounting If no new self locking nuts are available apply Loctite 243 to the thread of the old nuts If the thread is damaged replace the screws and nuts Do not use toothed disks or split washers for the engine fastening bolts since they will work their way into the frame components and become loose Always use self locking nuts Let the motorcycle cool down before servicing to avoid being burned Pro...

Page 36: ... to reduce damping during compression Make the same damping rate adjustment to both fork legs STANDARD ADJUSTMENT Turn adjusting screw clockwise as far as it will go Turn 15 clicks in a counterclockwise direction MAINTENANCE WORK ON CHASSIS AND ENGINE BASIC SETTING FORK WP 4860 ROMA Supermoto Supermoto Prestige Driving Comfort Basic Setting Driving Sport Maximum Payload Fahrer Komfort Basic Settin...

Page 37: ...ockwise as far as it will go Turn 15 clicks in a counterclockwise direction STANDARD ADJUSTMENT HIGH SPEED Turn adjusting screw 2 wrench size 15 mm clockwise as far as it will go Turn 1 5 turns in a counterclockwise direction The damping unit of the shock absorber is filled with high compression nitrogen Never try to take the shock absorber apart or to do anymaintenance work yourself Severe injuri...

Page 38: ...re injuries could be the result Breathing the fork legs Breath the fork legs regularly see Maintenance Schedule To breath place the motorcycle on the side stand and briefly remove the bleeder screws 2 to allow any overpressure to escape from the fork Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leak ing it is recommended to open the breather plugs befo...

Page 39: ...loose wheel spindle can cause the motorcycle s handling performance to become instable and cause it to crash Checking the chain tension Place the motorcycle on the side stand Switch the transmission to neutral and push the chain up The distance between the chain and swing arm should be 5 mm 0 2 in at the vertical rib when the upper part of the chain is tensioned see drawing Correct the chain tensi...

Page 40: ...sed sprockets Chain maintenance Maintenance of the X ring chain is reduced to a minimum Rinse off any heavy dirt with plenty of water Residual used grease must be removed prior to lubrication Motorex Chain Clean 611 After drying use a chain spray specially designed for X ring chains Motorex Chainlube 622 Strong No lubrication is allowed to reach the rear tire or the brake disk eitherwise the road ...

Page 41: ...rake pads always have the best possible contact to the brake disk For safety reasons always have maintenance work and repairs to the brake system performed by an authorized KTM workshop BRAKE PADS The brake pads mounted by KTM were tested at length to guarantee maximum braking per formance and are listed in the homologation papers Brake pads available in the accessory trade are often not authorize...

Page 42: ...n DOT 4 and is safer for high performance applications Brake fluid DOT 5 1 is a poly ethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motorcycle gaskets and brake hoses are not designed for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture...

Page 43: ...l times for best performance If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down In this case consult an authorized KTM dealer immediately Have the brake fluid changed at an authorized KTM workshop every 2 years Checking the front brake fluid level 690 Supermoto Prestige The brake fluid reservoir for the front brake is loca...

Page 44: ...ake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed If the brake pads are replaced too late when the lining is partly or completely worn off the steel parts on the brake pads will grind against the brake disks This significantly decreases the braking effect and destroys the brake disks ...

Page 45: ... pad will rub against the brake disc imparing the braking effect and destroying the brake disc MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear brake fluid level The brake fluid reservoir for the rear brake is located on the rear right of the vehicle and has a MIN and a MAX mark The brake fluid level may not fall below the MIN mark when the vehicle is parked in an upright position If the b...

Page 46: ...45 ...

Page 47: ...d ground and are correctly mounted The front wheel should not touch the ground MAINTENANCE WORK ON CHASSIS AND ENGINE 46 Remove the screws 1 from the brake caliper and carefully pull the brake caliper off the brake disk towards the rear Loosen the collar screw 2 and the clamping screws 3 on both fork leg axle passages Unscrew the collar screw approx 8 turns press on the collar screw with your hand...

Page 48: ...usly com press the fork several times to align the fork legs Torque the clamping screws 3 on both fork stubs to 15 Nm Actuate the hand brake until you feel the pressure point and check whether the front wheel can easily be turned Remove the rear stand If you do not have a torque wrench to mount the wheel have the torques corrected by an authorized KTM workshop as soon as possible A loose wheel spi...

Page 49: ... remove the chain from the rear sprocket Pull back the rear wheel together with the brake caliper support 4 until the brake caliper support can be tilted to the side Carefully lift the rear wheel out of the swing arm Do not operate the rear brake when the rear wheel has been dismounted Always place the wheel on the ground with the brake disc pointing upwards Otherwise the brake disc may be damaged...

Page 50: ... be in the same position on the left and right in relation to the reference marks B Before you tighten the collar nut to 90 Nm press the rear wheel towards the front to allow the chain tensioner to rest against the clamping screws If you don t happen to have a torque wrench at hand make sure you have the tighten ing torque corrected by a KTM dealer as soon as possible A loose wheel spindle can cau...

Page 51: ...h with the rear sprocket upwards and put the wheel spindle in the hub Now hold the rear wheel firmly and try to turn the rear sprocket The rear sprocket may not turn more than maximum 5 mm 0 2 in measured on the outside If the play in the chain wheel is larger all 6 shock absorption rubbers are to be replaced Check the shock absorption rubbers for signs of damage and dirt If the shock absorption r...

Page 52: ...r pressure to the motorcycle s total weight Proper pressure ensures optimum driving comfort and extends the life of your tires Do not mount tires which have not been approved by KTM Other tires could have adverse effects on the way your motorcycle rides Use tires of the same brand and type for the front and rear wheels For your own safety replace damaged tires immediately Worn tires can have a neg...

Page 53: ...tank and the spoiler to avoid damage Detach and remove the rubber band 3 First disconnect the negative terminal then the positive terminal from the battery Take the battery out of the frame towards the right To mount position the battery with the terminals facing the front see photo connecting the negative terminal to the battery last Mount the positive terminal cover and the rubber band Carefully...

Page 54: ...off load voltage and startability of the battery and generator It is impossible to over charge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the battery will run down and sulfa tize destroying the battery MAINTENANCE WORK ON CHASSIS AND ENGINE 53 Do not remove the cover...

Page 55: ...e that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 30 Ampere Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be repaired An inexpert treatment could damage the whole electrical installation Contact a specialized KTM dealer should defects of the electric system occur more frequently Moun...

Page 56: ...10 6 Horn brake light turn signal alarm system optional 10 7 High beam low beam parking light tail light license plate lamp 10 8 for attachments switched with the ignition 10 9 for attachments positive supply 10 10 SPARE Spare fuses 10 15 Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM ...

Page 57: ... the lamp engage in the recess B in the headlight Mount the bulb socket rubber cap and connector Position the headlight mask mount the screws and tighten to 5 Nm MAINTENANCE WORK ON CHASSIS AND ENGINE 56 Replacing the headlight lamp Remove the 4 screws 1 and carefully remove the headlight mask Never touch the glass of the bulb with your fingers The glass of the bulb must remain absolutely free fro...

Page 58: ... a level surface at a height corresponding to the center of the headlight Position your motorcycle loaded ready for the trip 5 meters 16 4 ft away from the wall and switch on the low beam The light dark cut off line should be 5 cm 2 in under the mark see drawing Replacing the flasher bulbs Remove the screw on the back of the turn signal carefully fold the lens 1 towards the motorcycle and remove S...

Page 59: ... Possible causes Slow riding with large loads at a higher air temperature If possible increase your running speed so that more air can blow through the radiators Should the warning light still be on off after 1500 meters 1 mile stop immediately switch off the engine and look for other possible causes The cooling fan on the radiator is not working The cooling fan must be running when the cooling li...

Page 60: ...d in the cooling system is controlled by a valve in the radiator cap 5 a water temperature rising up to 125 C 257 F is admissi ble without fear of problems Any excess cooling liquid caused by thermal expansion is conducted to the compensating tank 6 It will be sucked back in as soon as the temperature in the cooling system drops Checking the cooling liquid level in the compensating tank Check the ...

Page 61: ...adiator If any cooling liquid is missing the cooling system is probably leaking Have the cooling system checked at an authorized KTM workshop If possible check the cooling liquid level when the engine is cold If you need to remove the radiator cap when the engine is hot hold the cap with a cloth and open slowly allow ing any excess pressure to escape danger of scalding If more than 0 5 0 13 USgal ...

Page 62: ...lly remove it Cover the cap with a cloth and open slowly to allow excess pressure to escape can poten tially cause serious burn injuries If necessary pour cooling liquid into the radiator up to the upper edge of the filler neck mount the radiator cap and rest the motorcycle on the side stand again Fill the compen sating tank with cooling liquid until it reaches a level between the MIN and MAX mark...

Page 63: ...ply excessive force Checking the oil level of the hydraulic clutch 690 Supermoto To check the oil level in the master cylinder of the clutch remove the cover For this pur pose remove screws and cover 2 together with the rubber boot 3 The oil level in the hor izontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid...

Page 64: ...andlebar instruments may damage the fuel tank Checking the oil level of the hydraulic clutch 690 Supermoto Prestige The oil level should be between the MIN and MAX marks with the master cylinder in a horizontal position If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 available from your authorized KTM workshop KTM uses biodegradable hydraulic mineral oil to actuate the ...

Page 65: ...e oils that meet the JASO MA quality requirements see information on the can KTM recommends Motorex Cross Power 4T in the 10W 60 viscosity for all temperatures MAINTENANCE WORK ON CHASSIS AND ENGINE 64 Checking and adjusting the throttle cable play You should feel 3 5 mm free travel on the throttle grip when you start to turn it To adjust loosen the counternut 1 turn the adjusting screw 2 as requi...

Page 66: ...derfill the engine case MAINTENANCE WORK ON CHASSIS AND ENGINE 65 Checking the engine oil level Check the engine oil level when the engine is warm at least 5 bars on the temperature indi cator Place the motorcycle on a level surface not on the side stand Wait 30 seconds to allow the oil level to settle in the engine The oil level should be between the MIN and MAX marks Add engine oil if necessary ...

Page 67: ...ar ranty will become void if you change the oil yourself during the warranty period NOTE Clean the 2 oil screens and replace the 2 oil filters after each oil change The engine oil change is to be carried out when the engine is still warm An engine having been run warm and the engine oil in it is very hot do not burn yourself Rest the motorcycle on the side stand on a level surface Place a pan unde...

Page 68: ... the plugs cover and both oil screens Clean all rubber seal rings and check for damage replace if necessary Clean the sealing areas on the engine case Insert the oil screen 6 in the engine case as illustrated mount the plug and tighten to 15 Nm Use the same procedure to mount the oil screen on the right side of the engine MAINTENANCE WORK ON CHASSIS AND ENGINE 67 ...

Page 69: ...eal ring and tighten to 20 Nm Unscrew the plug 1 Add 2 liters 0 53 USgal of fully synthetic 10W 60 engine oil accord ing to JASO MA quality requirement e g Motorex Cross Power 4T 10W 60 and remount the plug Start the engine and allow to run warm in neutral until 5 bars on the temperature indicator light up Switch off the engine and check the engine oil level see Checking the engine oil level Check...

Page 70: ...switch the gear to neutral and switch the emergency OFF switch on do not accelerate while starting the engine Recharge the battery and investigate the causes for discharg ing contact an authorized KTM workshop Replace fuse 1 2 3 or 4 in the fuse box Remove the seat move the tank back and replace the main fuse Check ignition lock and emergency OFF switch contact an authorized KTM workshop Contact a...

Page 71: ...ine will not reach full power Air filter fuel filter heavily soiled Error in the injection system Have the air filter fuel filter replaced at an authorized KTM workshop Visit an authorized KTM workshop Engine overheats Insufficient cooling liquid Radiator fins are extremely dirty Foam forms in cooling system Radiator hose is kinked or damaged Thermostat defective Blown fan fuse Refill cooling liqu...

Page 72: ...uel Replace fuse 1 2 or 4 High oil consumption Engine oil level too high Engine oil too thin viscosity Kink in engine vent hose Check engine oil level when the engine is warm correct if necessary Use thicker engine oil see chapter Engine oil Remove the seat move the tank back and check engine vent hoses Headlight and position light fail Blown fuse Replace fuse 7 Turn signal brake light and horn do...

Page 73: ...p cable is damaged or con tacts on the cable connector have oxidized Check the pickup cable for damage visit an authorized KTM workshop The blink code indicates which component is affected by an error This allows the error to be identified if no diagnosis tool is available BLINK CODE SIGNAL COMPONENT ERROR DESCRIPTION ENGINE 02 Pulse generator Malfunction Stalls 06 Throttle sensor Output signal to...

Page 74: ...oil Malfunction Stalls 41 Fuel pump relay Short circuit to ground positive Stalls 45 Lambda probe heater Short circuit to ground positive Continues to run 53 Purge valve for carbon canister Short circuit to ground positive Continues to run 54 Secondary air valve Short circuit to ground positive or interruption Continues to run 55 EPT electric motor control unit Supply voltage too low high Continue...

Page 75: ...er the motorcycle has cooled down oil or lubricate all of the friction bearings and bearing positions and treat the chain with chain spray Treat all bare areas except brake disks with a corrosion inhibitor e g Motorex Protect Shine The exhaust pipes and mufflers are made of stainless steel and should be treated with a suitable care product To prevent failures in the electric system you should trea...

Page 76: ...ls as a possible humidity might not be able to escape and could cause corrosion It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust RE INITIATION AFTER TIME OF STORAGE Mount the charged battery pay attention t...

Page 77: ... 120 70 R17 M C 58H 120 70 ZR17 M C 58W Air pressure Road driver only 2 0 bar 28 psi Road with passenger maximum payload 2 0 bar 28 psi Authorized rear tires BRIDGESTONE Battlax BT090R PRO METZELER Sportec M3 160 60 R17 M C 69H 160 60 ZR17 M C 69W Air pressure Road driver only 2 0 bar 28 psi Road with passenger maximum payload 2 2 bar 31 psi Fuel tank capacity 13 liters 3 44 USgal 2 5 liters 0 66 ...

Page 78: ...5 mm 9 65 in Dry weight 154 kg 339 5 lbs Max axle load front 150 kg 330 7 lbs Max axle load rear 200 kg 440 9 lbs Max total load 350 kg 771 6 lbs FORK 690 SUPERMOTO 690 SUPERMOTO PRESTIGE Type 14 18 7C 07 WP Suspension 14 18 7C 08 WP Suspension Spring 5 2 430 5 2 430 Air chamber length 100 mm 39 37 in 100 mm 39 37 in Fork oil SAE 2 5 SAE 2 5 SHOCK ABSORBER 690 SUPERMOTO 690 SUPERMOTO PRESTIGE Type...

Page 79: ...clicks 20 15 10 10 Rebound adjuster clicks 20 15 10 10 20 15 10 10 BASIC SETTING SHOCK ABSORBER WP 4618 SUPERMOTO SUPERMOTO PRESTIGE Driving Comfort Basic Setting Driving Sport Maximum Payload Driving Comfort Basic Setting Driving Sport Maximum Payload Compression adjuster Low Speed clicks 20 15 10 10 Compression adjuster High Speed turns 2 1 5 1 1 Rebound adjuster clicks 20 15 10 10 20 15 10 10 S...

Page 80: ...Loctite 222 3 Nm Screw for starter cable starter M5 3 Nm Pushrod ball joint foot brake cylinder M6 Loctite 243 10 Nm Remaining screws for tank M6 6 Nm Screw for compensating tank rear wheel brake M6 5 Nm Screw for battery rack control unit holder M6 3 Nm Screw for fuel cock M6 6 Nm Screw for front rear brake disk M6 Loctite 243 14 Nm Screw for foot brake cylinder M6 Loctite 243 10 Nm Screw for hor...

Page 81: ...est bracket M8 Loctite 243 25 Nm Screw for upper triple clamp M8 12 Nm Screw for lower triple clamp M8 15 Nm Screw for fork stub M8 15 Nm Screw for grip M8 6 Nm Screw for steering stem clamping M8 20 Nm Screw for header silencer M8 copper paste 25 Nm Screw for handlebar clamp M8 20 Nm Screw for upper subframe M8 Loctite 243 35 Nm Screw for side stand bracket M8 Loctite 243 25 Nm Screw for tank bea...

Page 82: ...obe M12x1 25 24 5 Nm Nut for frame connecting lever rocker arm swinging fork M14x1 5 100 Nm Nut for swing arm pivot M16x1 5 100 Nm Nut for engine sprocket M20x1 5 Loctite 243 80 Nm Screw for steering head M20x1 5 12 Nm Adjusting ring for swing arm support M24x1 5 25 Nm Screw for front wheel spindle M24x1 5 40 Nm Nut for rear wheel spindle M25x1 5 90 Nm Remaining chassis screws M5 M6 M8 M10 4 Nm 10...

Page 83: ...ing Two cylinder roller bearing Conrod bearing Needle bearing Piston pin bearing Bronze bushing Piston Light alloy forged Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Semi dry sump with 2 Eaton pumps Engine oil Fully synthetic 10W 60 engine oil according to the JASO T903 MA specification Motorex Cross Power 4T 10W 60 Quantity of engine oil approx 2 ...

Page 84: ...ction Ignition system breakerless transistorized electronic ignition system with digital ignition advance Alternator 12V 224W at 5000 rpm Spark plug NGK LKAR8AI 9 Electrode distance 0 9 mm 0 035 in Cooling system liquid cooled Cooling liquid 1 2 liter 0 317 USgal 50 antifreeze 50 distilled water at least 25 C 13 F Starting aid electric starter ...

Page 85: ...diator 60 Checking the engine oil level 65 Checking the front brake fluid level 690 Supermoto Prestige 42 Checking the front brake pads 43 Checking the oil level of the hydraulic clutch 690 Supermoto Prestige 63 Checking the oil level of the hydraulic clutch 690 Supermoto 62 Checking the rear brake fluid level 44 Checking the rear brake pads 44 Checking the shock absorption rubbers in the rear hub...

Page 86: ... Main fuse 54 MAINTENANCE WORK ON CHASSIS AND ENGINE 34 OPERATION INSTRUMENTS 7 Owner s manual 16 PERIODIC MAINTENANCE SCHEDULE 30 Rebound damping of fork 18 Rebound damping of shock absorber 19 Refilling engine oil 65 Replacing the flasher bulbs 57 Replacing the headlight lamp 56 Running in the LC4 engine 20 Seat lock removing the seat 15 SERIAL NUMBER LOCATIONS 6 Shift lever 16 Shifting Riding 2...

Page 87: ...CONSUMER INFORMATION FOR USA ONLY 86 under seat on fframe tube L S on frame tube on rear fender under seat Sticker positions 5 4 on frame tube R S on frame tube L S 3 on frame tube R S 6 7 8 2 1 ...

Page 88: ...eed clicks Compression High Speed turns Rebound clicks Spring preload mm Comfort 20 20 12 BASIC SETTING 15 15 12 Sport 10 10 12 Max payload 10 10 12 8 Suspension setting 7 Before you go for the first ride 5 Vehicle emission 2 Type label CAN 6 Noise emission 1 EAVP 5 m m 5 m m 750 04 099 000 4 Chain tension 3 Type label USA ...

Page 89: ...01 Telephone 440 9853553 TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to t...

Page 90: ...690 LC4 SUPERMOTO KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at 01 2007 FOTO MITTERBAUER KTM Group Partner ART NR 3 211 147 DE BEDIENUNGSANLEITUNG 2007 ...

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KTM 690 LC4, Owner'S Manual

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