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OWNER'S MANUAL

2009

690 Rally Factory Replica

ART. NO. 3211361en

Содержание 2009 690 Rally Factory Replica

Страница 1: ...OWNER S MANUAL 2009 690 Rally Factory Replica ART NO 3211361en...

Страница 2: ......

Страница 3: ...e technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produ...

Страница 4: ...e motorcycle from the work stand 29 Checking the basic chassis setting with the rider s weight 29 Compression damping of shock absorber 29 Adjusting the compression damping of the shock absorber 29 Ad...

Страница 5: ...or idle 65 Carburetor adjusting the idle speed x 66 Checking the engine oil level 67 Changing engine oil and filter cleaning oil screens x 67 Draining the engine oil x 67 Removing the oil filter x 68...

Страница 6: ...hnical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the speci...

Страница 7: ...aims will be recognized No warranty claims can be granted for damage resulting from manipulations and or alterations to the vehicle Fuel oils etc You should use the fuels oils and greases according to...

Страница 8: ...ill immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the...

Страница 9: ...1 11 Type label is fixed to the right of the steering head 3 3 Key number 500125 10 The key number is stamped on the key strap 3 4 Engine number 600003 10 The engine number is stamped on the left side...

Страница 10: ...LOCATION OF SERIAL NUMBERS 8 3 6 Shock absorber part number 600026 10 Shock absorber part number is attached at the shock absorber unit to the rear of the direction of travel...

Страница 11: ...ion switch 600044 10 The ignition switch is located to the left of the indicator lamp on the instrument support Possible states Ignition off Ignition switch flipped up In this position the ignition ci...

Страница 12: ...sher switch 600004 10 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher switch is in the central position Flasher light left on Flasher switch tu...

Страница 13: ...display Press the button for 3 5 seconds The Setup menu opens and the active functions are displayed Press the button repeatedly until the Km h Mph display flashes Km h adjusting Press the button Mph...

Страница 14: ...changes to the next func tion Deactivating a function Press the button The icon disappears from the display and the display changes to the next function Activate or deactivate all functions accordingl...

Страница 15: ...y changes to the ODO display mode The H display mode is suppressed during the journey Press the button No function Press the button No function Press the button for 3 5 seconds The display changes to...

Страница 16: ...led with A1 average speed 1 and S1 stop watch 1 Info If 999 9 is exceeded the values of TR1 A1 and S1 are automaticallt reset to 0 0 Press the button No function Press the button No function Press the...

Страница 17: ...on No function Press the button No function Press the button for 3 5 seconds Press the button briefly Next display mode 4 25 Display mode SPEED S1 stop watch 1 400327 01 Press the button briefly and r...

Страница 18: ...trip master 2 Increases value of TR2 Reduces value of TR2 Deletes value of TR2 Next display mode Disply mode SPEED A1 average speed 1 No function No function Displays of TR1 A1 and S1 are reset to 0...

Страница 19: ...at 600045 10 The right fuel tank is filled via filler cap and the left fuel tank is filled via filler cap 600046 10 The rear fuel tank is filled via filler cap 4 29 Fuel tap 600008 10 Fuel tap is loca...

Страница 20: ...vating the choke function frees an opening through which the engine can draw extra fuel This gives a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke funct...

Страница 21: ...nly The side stand and or the frame could be damaged and the motorcycle could fall over To park the motorcycle remove the rubber band fold down the side stand with your foot and rest the motorcycle ag...

Страница 22: ...ering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock 4 37 Tool set 600805 10 The tool set i...

Страница 23: ...not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never le...

Страница 24: ...missible front axle load 190 kg 419 lb Maximum permissible rear axle load 250 kg 551 lb Run the engine in 5 2 Running in the engine During the run in phase do not exceed the specified speed in the res...

Страница 25: ...nd can 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 a closed space without an effective exhaust...

Страница 26: ...Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake if necessary and close the throttle at the same time Pull the clu...

Страница 27: ...side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Apply the brakes and shift into neutral With the engine idling flip the ignition switch up until th...

Страница 28: ...l tank half front right approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Rear fuel tank approx 18 0 l 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Total fuel capacity approx 3...

Страница 29: ...les for damage and routing without sharp bends Clean the fuel tank breather hoses checking for damage and routing with out sharp bends Check the headlamp setting Treat electric contacts with contact s...

Страница 30: ...components including shafts x Check the crankshaft connecting rod and cylinder x Check the clutch x Check the camshaft rocker arm and valves x K100A every 10 000 km 6 214 mi J1A annually J2A every 2...

Страница 31: ...your weight is above or below the standard range you have to adjust the basic setting of the suspension components accord ingly Small weight differences can be compensated by adjusting the spring pre...

Страница 32: ...rber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself 600053 10 Turn adjusting scr...

Страница 33: ...full protective clothing in a normal sitting position feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between...

Страница 34: ...ition feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between the rear axle and a fixed point Make a note of...

Страница 35: ...ews and splash protector 600094 10 Remove screw 600095 10 Remove screw Remove shock absorber 8 14 Installing the shock absorber 600096 10 Position the shock absorber Mount the screw with the washers a...

Страница 36: ...compensated by the spring preload However if your fork is often overloaded hard end stop on compression you must fit harder springs to avoid damage to the fork and frame 8 16 Adjusting the compressio...

Страница 37: ...ove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the work stand p 29 8 19 Cleaning dust boots of fork le...

Страница 38: ...ing the bearing and the bearing seats in the frame can be damaged after time Jack up the motorcycle p 29 Remove the steering damper 400189 10 Move the handlebar to the straight ahead position Move the...

Страница 39: ...ring head M20x1 5 12 Nm 8 9 lbf ft Lock the screw and nut Guideline Lock nut top steering head M20x1 5 25 Nm 18 4 lbf ft 600100 12 Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft...

Страница 40: ...in drill hole you will achieve better riding stability on fast stretches Fork offset No mark 22 mm 0 87 in 8 25 Handlebar position 0 0 B B 0 0 A A 400361 10 On the upper triple clamp there are 2 holes...

Страница 41: ...nt and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Condition Spacer mounted Use a M10x35 screw Condition Without a spacer Use a M10x25 screw Info Positio...

Страница 42: ...ental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info The service life of the chain d...

Страница 43: ...e of the joint faces forward riding direction The engine sprocket rear sprocket and chain should always be replaced together Check the chain guides for firm seating and wear 8 32 Adjusting chain tensi...

Страница 44: ...s Remove the cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level of the hydraulic...

Страница 45: ...dlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do...

Страница 46: ...tal hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This...

Страница 47: ...ke caliper support 8 42 Installing the front brake linings x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and...

Страница 48: ...authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulati...

Страница 49: ...pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications 400291 13 Loosen the nut and use...

Страница 50: ...Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil sea...

Страница 51: ...brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Bra...

Страница 52: ...ronmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake flui...

Страница 53: ...ce bushing 8 53 Mounting the front wheel x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with br...

Страница 54: ...when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster 600036 10 Withdraw the wheel spindle only enough to allow the rear wheel...

Страница 55: ...ttach the chain 600114 10 Position the chain adjuster Mount nut but do not tighten it yet Adjust the chain tension p 41 Operate the foot brake lever repeatedly until the brake linings lie on the brake...

Страница 56: ...air pressure on road Front 1 5 bar 22 psi Rear 1 5 bar 22 psi If the tire pressure does not meet specifications Correct tire pressure Mount dust cap 8 58 Checking spoke tension Warning Danger of acci...

Страница 57: ...trim at the guides and Info When positioning the trim exercise caution with the quick releases to ensure that you do not damage the trim 600081 11 Align the trim and attach it with the quick releases...

Страница 58: ...and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is...

Страница 59: ...and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clot...

Страница 60: ...el tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fu...

Страница 61: ...th sides but do not tighten it yet Align the main silencer Mount and tighten screws and on both sides Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Tighten screw on both sides Guideline Rema...

Страница 62: ...e with a rider the light dark boundary must lie exactly on the lower mark If the light dark boundary does not meet specifications Adjust the headlamp p 60 8 70 Adjusting the headlamp Remove the trim p...

Страница 63: ...d tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Attach the plus cable and replace the plus pole cover Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Attach the minus ca...

Страница 64: ...to avoid damage to the motor cycle s electronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to...

Страница 65: ...in eyes and clothing If fuel 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 imm...

Страница 66: ...coolants out of the reach of children 600067 10 Condition Engine is cold Stand the motorcycle upright on a horizontal surface Remove compensating tank cap and the radiator cap Check antifreeze of coo...

Страница 67: ...the front of the air filter box and swing down 600803 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 56 8 80 Carburetor idle The idle setting of t...

Страница 68: ...ghest idle speed Info If there is a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extreme sport motorcyclist will set the mixture about 1 4 of a turn bac...

Страница 69: ...l x p 70 Mount the motor guard p 59 8 84 Draining the engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gl...

Страница 70: ...leaning substances brake fluid batteries etc according to regulations Remove the front fuel tank p 56 Place a suitable container under the engine 600083 10 Remove screws Take off the oil filter cover...

Страница 71: ...e filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine 600077 10 Remove plug with oil screen and O ring 600079 10 Remove plug...

Страница 72: ...ft Install the fuel tank p 56 8 88 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 600060 11 Remove the screw cap on the clu...

Страница 73: ...ngine oil SAE 20W 60 p 96 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend making an oil change in this case Mount and tighten screw cap Danger Dang...

Страница 74: ...generator x Check the generator x Socket connector of CDI control device pulse generator or ignition coil oxidized Clean the socket connector and treat it with contact spray Water in carburetor or jet...

Страница 75: ...k breathers Check the fuel filter Check the fuel sieve of the fuel tanks Clean the fuel tap Check adjust the carburetor components x Check the fuel pump x Air filter very dirty Clean the air filter x...

Страница 76: ...e cleaner and a soft sponge If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After the motorcycle has been thoroughly cleaned wi...

Страница 77: ...nge the engine oil and filter clean the oil screens x p 67 Check the coolant level and antifreeze p 64 Drain the fuel from the tanks into a suitable container Drain the fuel from the carburetor into a...

Страница 78: ...rotor pumps Primary transmission 36 79 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 23 26 5th gear 24 25 6th ge...

Страница 79: ...hain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw large clutch cover M6 10 Nm 7 4 lbf ft Screw locking lever M6 10 Nm 7 4 lbf...

Страница 80: ...r for temperature switch on cylinder head M12x1 5 12 Nm 8 9 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil...

Страница 81: ...ry Replica Carburetor type KEIHIN FCR MX 41 Carburetor identification number 4100C Needle position 5 th position from top Idle mixture adjusting screw Open 2 turns Main jet 160 Jet needle OBDYU OBEKR...

Страница 82: ...Secondary drive ratio 16 44 Rear sprockets available 43 44 45 Chain 5 8 x 1 4 Wheelbase 1 535 10 mm 60 43 0 39 in Steering head angle 62 5 Seat height unloaded 980 mm 38 58 in Ground clearance unloade...

Страница 83: ...com 15 3 Capacity fuel Fuel tank capacity Fuel tank half front left approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Fuel tank half front right approx 9 0 l 2 38 US gal Super unleaded...

Страница 84: ...preload spacer s 502 mm 19 76 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 8 N mm 27 4 lb in Weight of rider 75 85 kg 165 187 lb 5 0 N mm 28 6 lb in Gas pressure 1 8 bar 26 psi Fork length 95...

Страница 85: ...g Standard 20 clicks Spring preload Standard 14 mm Spring rate Weight of rider 65 75 kg 143 165 lb 88 N mm 502 lb in Weight of rider 75 85 kg 165 187 lb 92 N mm 525 lb in Weight of rider 85 95 kg 187...

Страница 86: ...ing screws chassis M8 25 Nm 18 4 lbf ft Screw beam engine support bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw foot brake pedal M8 25 Nm 18 4 lbf ft Loc...

Страница 87: ...85...

Страница 88: ...M A _ C 2 R A _ C 2 S 1 3 2 A 0 1 1 2 2 F A 0 1 1 2 3 F A 0 1 1 2 4 F A 0 1 1 2 5 F A 5 1 1 2 6 F A 5 1 2 7 F A 5 1 2 8 F A 0 1 1 2 1 F 5 X 6 D 3 2 4 3 1 M 0 3 A 4 F A _ C 1 M 1 G 1 K 4 2 3 1 U C_AU...

Страница 89: ...tarter button Cable colors 1 Green 2 Green 3 Green 4 Green 5 Green 6 Green 7 Yellow red 8 Green 9 Yellow red 10 Yellow red 11 Yellow red 12 Yellow red 13 Yellow red 14 Yellow red 15 Orange 16 Black or...

Страница 90: ...ack yellow 52 Brown 53 Brown 54 Brown 55 Brown 56 Black 57 Black red 58 Black red 59 White green 60 Black green 61 Green red 62 Pink 63 Orange 64 White red 65 Yellow blue 69 Brown 131 Yellow 133 Black...

Страница 91: ...WIRING DIAGRAM 89...

Страница 92: ...1 7 D 1 3 9 0 1 5 C 1 0 4 3 1 2 L A _ C 2 T A _ C 1 L 1 2 3 M A _ C 3 R A _ C 1 B 2 1 3 t 2 B 1 1 2 L 1 3 2 4 5 6 8 7 9 0 1 1 1 6 1 5 1 4 1 3 1 2 1 6 1 BX _ C 6 A 1 BJ _ C 1 AY _ C 6 X 1 1 2 37 38 0...

Страница 93: ...Throttle position sensor B2 Temperature switch for indicator lamp L1 Pulse generator L2 Ignition coil Cable colors 15 Orange 32 Brown 33 Brown 34 Blue 35 Yellow 36 Black 37 Gray 38 black blue 39 Gray...

Страница 94: ...2 H6 1 2 H10 1 2 H8 1 2 H7 C_DI 2 1 2 9 1 H 1 2 8 1 H 1 2 7 1 H 1 2 6 1 H 1 2 5 1 H 3 C 1 7 1 3 1 3 0 3 X 7 0 4 X I H O L t h g i l P 4 3 2 1 5 1 6 C A _ C 1 A B _ C 1 F B _ C 6 C B _ C 9 S 6 C 1 2 4...

Страница 95: ...light optional H15 Flasher indicator light H16 Idling speed indicator lamp H17 Indicator lamp for the coolant temperature H18 High beam indicator light H19 Oil pressure indicator lamp K2 Flasher rela...

Страница 96: ...olet 81 Violet 82 Black 83 Black 84 Black 85 Black 86 Black 87 Black 88 Black 89 Black 90 Green white 91 Brown 92 White 93 Black brown 94 White yellow 95 White 96 White 97 White 98 Brown 99 Brown 100...

Страница 97: ...WIRING DIAGRAM 95 116 White 117 White 118 White 119 Brown 120 Brown 121 Brown 122 Brown 123 Brown 124 Brown 125 Brown 126 Brown 127 Black yellow 128 Black green 129 Red 130 Brown...

Страница 98: ...rrosion antifreeze 50 Distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 99 SAE p 99 SAE 10W 60...

Страница 99: ...ine Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Mot...

Страница 100: ...upplier Motorex Accu Contact High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Specification KTM recommends Motorex products Supp...

Страница 101: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wit...

Страница 102: ...level 42 Clutch lever 9 adjusting 42 Compression damping fork adjusting 34 Coolant level checking 63 Coolant level and antifreeze checking 64 D Dust boots cleaning 35 E Electric starter button 9 Engin...

Страница 103: ...6 removing 55 Service schedule 27 28 Shift lever gears 18 Shifting riding 24 Shock absorber adjusting the spring preload 31 compression damping adjusting 29 rebound damping adjusting 30 removing 33 st...

Страница 104: ...3211361en 3211361en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 08 2008 Photo Mitterbauer...

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