KTM 690 Duke (2013) manual

OWNER'S MANUAL 20 13 690 Duke EU 690 Duke AUS/UK 690 Duke MAL 690 Duke R EU 690 Duke R AUS/UK 690 Duke R MAL Art. no. 3211953en[...]

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DEAR KTM CUSTOME R 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle . You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. C[...]

DEAR KTM CUSTOME R 2 KTM-Sportmotorcy cle AG 5230 Mattighofen, Austria[...]

TABLE OF CONTENTS 3 TABLE OF CONTENTS 1 MEANS OF REPRESENTATION ............................ ............ 7 1.1 Symbols used ............................................. ......... 7 1.2 Formats used....................................................... 7 2 SAFETY ADVICE ..................... ............................ ............. 8 2.1 Use de[...]

TABLE OF CONTENTS 4 6.13 Closin g the filler cap .................. ........................ 40 6.14 Seat lock............................................... ............ 41 6.15 Tool set.................................................. ........... 41 6.16 Handr ails ................................................ .......... 42 6.17 Passe nger fo[...]

TABLE OF CONTENTS 5 11.15 Checking/rectifyin g the fluid level of the hydraulic clutch ................... ............................ .. 88 12 BRAKE SYSTEM ......................................... .................. 89 12.1 ABS/an tilock brake system ................. ................. 89 12.2 Adjust ing the basic position of the hand brake leve[...]

TABLE OF CONTENTS 6 18 CLEANING, CARE .......................................... ............. 152 18.1 Cleani ng the motorcycle .. ............................ ..... 152 18.2 Check s and maintenance steps for winter operation.......................... ............................ ... 154 19 STORAGE ...................................... ..........[...]

1 MEANS OF REPRESEN TATION 7 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technic al understanding. In the interest of yo[...]

2 SAFETY ADVICE 8 2.1 Use defi nition - intended use KTM sport motorcycles are designed and constructe d to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is only authorized for operation on public roads in the homologated version. 2.2 Safety a dvice A number of safety instructions [...]

2 SAFETY ADVICE 9 2.3 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measur es are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger t[...]

2 SAFETY ADVICE 10 1 Remov al or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases . 2 Remov al or puncturing of any part of the intake system. 3 Lack of proper maintena nce. 4 Replac ing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those spe[...]

2 SAFETY ADVICE 11 2.6 Protective clothing Warning Risk o f injury   Missing or poor protective clothing presents an increas ed safety risk. – Wear protective clothing (helmet, boots, glove s, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirem[...]

2 SAFETY ADVICE 12 2.9 Owner's M anual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains use- ful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for y[...]

3 IMPORTA NT NOTES 13 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM deale r.net ; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations an[...]

3 IMPORTA NT NOTES 14 It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe 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 components may be shown disassembled[...]

15[...]

4 VIEW OF VEHICLE 16 4.1 View of vehicle, front left side (exa mple) C00298-10[...]

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

4 VIEW OF VEHICLE 18 4.2 View of vehicle, rear right side (ex ample) C00299-10[...]

4 VIEW OF VEHICLE 19 1 Tool set ( p. 41) 1 Map ‑ Select switch 2 Light switch ( p. 27) 2 Headlight flasher switch ( p. 28) 2 Turn signal switch ( p. 28) 2 Horn button ( p. 27) 3 Filler cap 4 Ignition/steering lock ( p. 30) 5 Emergency OFF switch ( p. 29) 5 Electric starter button ( p. 29) 6 Hand brake lever ( p. 25) 7 Chassis number/type label 8 [...]

5 SERIAL NUMBE RS 20 5.1 Chassis number 602542-10 The chassis number 1 is stamped on the right side of the steering head. 5.2 Type lab el C00301-10 (690 D uke EU , 690 Duke MAL, 690 Duke R EU, 690 Duke R MAL) The type label 1 is located on the right side of the frame.[...]

5 SERIAL NUMBE RS 21 602549-10 (690 D uke AU S/UK, 690 Duke R AUS/UK) The type label 1 is located on the left side of the f rame. 5.3 Key num ber B00755-10 The key number 1 can be found on the KEYCODECARD . Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.[...]

5 SERIAL NUMBE RS 22 5.4 Engine n umber C00302-10 (Duke) The engine number 1 is located on the left side of the engine under the engine sprocket. 602550-10 (Duke R) The engine number 1 is located on the left side of the engine under the engine sprocket.[...]

5 SERIAL NUMBE RS 23 5.5 Fork par t numbe r C00303-10 The fork part number 1 is stamped on the inner side of the fork stub. 5.6 Shock a bsorber part number C00304-10 (Duke) The shock absorber part number 1 is on the left side of the shock absorber.[...]

5 SERIAL NUMBE RS 24 602551-10 (Duke R) The shock absorber part number 1 is found on the damper at the rear.[...]

6 CONTROL S 25 6.1 Clutch lever C00305-10 The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusti ng. 6.2 Hand brake lever 602570-10 (Duke) The hand brake lever 1 is fitted on the right side of the handlebar.[...]

6 CONTROL S 26 602552-10 (Duke R) The hand brake lever 1 is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. 6.3 Throttle grip B00922-10 The throttle grip 1 is fitted on the right side of the handlebar.[...]

6 CONTROL S 27 6.4 Horn button C00308-11 The horn button 1 is fitted on the left side of the handlebar. Possible states • Horn button in neutral position • Horn button pressed – The horn is operated in this position. 6.5 Light switch C00307-10 The light switch 1 is fitted on the left side of the handlebar. Possible states Low beam on – Ligh[...]

6 CONTROL S 28 6.6 Headlight flasher switch C00307-11 The headlight flasher switch 1 is fitted on the left side of the handlebar. Possible states • Headlight flasher switch in neutral position • Headlight flasher switch pressed – In this position, the headlight flasher (high beam) is actuated. 6.7 Turn signal switch C00308-10 The turn signal [...]

6 CONTROL S 29 6.8 Emergency OFF switch 602553-10 The emergency OFF switch 1 is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is inter- rupted, a running engine stops, and the engine cannot be started. Emergency OFF switch on – This position is necessary for operatio[...]

6 CONTROL S 30 6.10 Ignition/steerin g lock B00925-01 The ignition/steering lock 1 is located in front of the upper triple clamp. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed. Ignition on – In this position, [...]

6 CONTROL S 31 6.11.2 function buttons 401426-10 You can change the display mode with the MODE button 1 . Possible display modes are the odometer ( ODO ), trip master 1 ( TRIP 1 ), trip master 2 ( TRIP 2 ), and gear display ( GEAr ). Press the SET button 2 to reset the trip master 1 function ( TRIP 1 ) and trip master 2 func- tion ( TRIP 2 ) to 0.0[...]

6 CONTROL S 32 6.11.4 Combination instrumen t - indicator lamps 401428-01 The indicator lamps offer additional informatio n about the operating state of the motorcy- cle. Possible states The turn signal indicator light flashes green simultaneous ly with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up gr[...]

6 CONTROL S 33 6.11.5 Display 400836-01 When you switch on the ignition, all display segments light up for one second as a function check. 400881-01 LEnGth Following the display function check, the LEnGth wheel circumf erence is shown for one sec- ond. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series pro- duct[...]

6 CONTROL S 34 6.11.6 Speed display 401443-10 The speed 1 is 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 according to the country. Condition The motorcycle is stationary.[...]

6 CONTROL S 35 401444-01 – Switch on the ignition by turning the ignition key to the position . – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h . 6.11.8 Time 401443-11 The time is shown in area 1 of the display. Info After recon[...]

6 CONTROL S 36 401444-01 – Switch on the ignition by turning the ignition key to the position . – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. – Press the MODE button to set the hour. – Press the SET button to set the minu[...]

6 CONTROL S 37 401445-01 – Switch on the ignition by turning the ignition key to the position . – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0 . 6.11.12 Setting/resetting displa y TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999.9 . [...]

6 CONTROL S 38 6.11.13 TRIP F display 401447-01 If the fuel level drops to the reserve 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. 6.11.14 GEAr display 401418-01 In display mode GEAr , the gear cu[...]

6 CONTROL S 39 6.11.15 Coolant temperature indicator 700124-01 The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up. Possible states • Engine cold – Up to four bars light up. • Engine w[...]

6 CONTROL S 40 Warning Environmental hazard   Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. B00926-10 – Lift cover 1 of the filler cap and insert the ignition key in the lock. Note Danger of damage   Ignition key breakag e. – To take pressure o[...]

6 CONTROL S 41 6.14 Seat lock B00928-10 The seat lock 1 is located on the left side of the vehicle. It can be locked with the ignition key. 6.15 Tool set B00929-10 The tool set 1 is located under the passenger seat.[...]

6 CONTROL S 42 6.16 Handrails 602579-10 The handrails 1 are used for moving the motorcycle around. When you 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 folded up – For operation without a [...]

6 CONTROL S 43 6.18 Shift lever 602555-11 (Duke) The shift lever 1 is mounted on the left side of the engine. 602554-11 (Duke R) The shift lever 1 is mounted on the left side of the engine.[...]

6 CONTROL S 44 602555-10 (Duke) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 602554-10 (Duke R) The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears.[...]

6 CONTROL S 45 6.19 Foot brake lever C00313-10 (Duke) Foot brake lever 1 is located in front of the right footrest. 602556-10 (Duke R) Foot brake lever 1 is located in front of the right footrest. The rear brake is engaged with the foot brake lever.[...]

6 CONTROL S 46 6.20 Side stand C00312-10 (Duke) The side stand 1 is located on the left side of the vehicle. 602557-10 (Duke R) The side stand 1 is located on the left side of the vehicle. 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 startin[...]

7 PREPARIN G FOR USE 47 7.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgem ent being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk o f injury   Missing or poor protective clothing presents[...]

7 PREPARIN G FOR USE 48 Warning Danger of accidents   Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking. Info When using your vehicle, remember that others may feel disturbed by exce[...]

7 PREPARIN G FOR USE 49 – Avoid fully opening the throttle! 7.3 Loading the vehicle Warning Danger of accidents   Unstabl e handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle oper ational and with a full tank, driver and passenger with protective clothing and helme[...]

7 PREPARIN G FOR USE 50 Warning Danger of accidents   Unstabl e handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns   A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. – If you carry [...]

8 RIDING INSTRUC TIONS 51 8.1 Performing checks and vehicle care when preparing for use Info Before each use, check the state and roadworthiness of the vehicle. Make sure that the vehicle is in perfect technical condition before use. – Check the engine oil level. ( p. 146) – Check the brake fluid level of the front brake. ( p. 92) – Check the[...]

8 RIDING INSTRUC TIONS 52 8.2 Starting Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them 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 extraction system . Note Engi[...]

8 RIDING INSTRUC TIONS 53 Info Do not press the electric starter button until the combination instrument func- tion check is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start. Press the starter for a maximum of[...]

8 RIDING INSTRUC TIONS 54 8.3 Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully . 8.4 Shifting, riding Warning Danger of accidents   Abrupt load alteratio ns can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking action[...]

8 RIDING INSTRUC TIONS 55 Warning Danger of accidents   Danger of accidents caus ed by dangerous driving. – Comply with traffic regulations and ride defensively and foresigh tedly to detect sources of danger early on. Warning Danger of accidents   Reduced road grip with cold tires. – On every journey, take the first miles carefully at moder[...]

8 RIDING INSTRUC TIONS 56 – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Note Engine failure   Overheating of engine. – If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the coolant level in the ra[...]

8 RIDING INSTRUC TIONS 57 602554-10 (Duke R) – When conditions allow (incline, road situation , etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulli ng the clutch lever, shift into the next gear, release the clutch, and open the throttle. Info You can see the positions of the 6 forward gears in the figure. [...]

8 RIDING INSTRUC TIONS 58 Info From the flash rhythm you can deduce a two-digit number, the so-called blink code. The blink code tells you which component is affected by a fault. (Your authorized KTM workshop will be glad to help.) 8.5 Applying the brakes Warning Danger of accidents   Reduced brak ing efficiency due to a wet or dirty brake system[...]

8 RIDING INSTRUC TIONS 59 Warning Danger of accidents   Greater stoppi ng distance due to ABS. – Braking should be appropriate to the driving situation and the road conditions. Warning Danger of accidents   Excessi vely forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents  [...]

8 RIDING INSTRUC TIONS 60 8.6 Stopping, parking Warning Risk o f misap propriation   Usa ge by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons . If you leave the vehicle, lock the steering and remove the ignition key. Warning Danger of burns   Some vehicle com[...]

8 RIDING INSTRUC TIONS 61 – Switch off the ignition by turning the ignition key to the position . Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the eng[...]

8 RIDING INSTRUC TIONS 62 401448-01 – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 8.8 Refueling Danger Fire ha zard   Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be car[...]

8 RIDING INSTRUC TIONS 63 – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard   Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. B00935-10 – Switch off the engine. – Open the filler cap. ( p. 39) – Fill[...]

9 SERVICE SCHED ULE 64 9.1 Service schedule K10N K100 A K200A Check the functioning of the electrical equipment. • • • Read out the fault memory using the KTM diagnostics tool. x • • • Check the measured service values with the KTM diagnostics tool. x • • Change the engine oil and filter, clean the oil screens. x ( p. 146) • • ?[...]

9 SERVICE SCHED ULE 65 K10N K100 A K200A Check the valve clearance. x • • Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrec t routing. x • Check the antifreeze and coolant level. ( p. 135) • • • Check the cables for damage and routing without sharp bends. x • • Change the air[...]

10 TUNING THE CHASSIS 66 10.1 Fork/shock absorber (Duke R) 602586-10 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table 1 . You can find the table on the subframe under the passenger seat. These adjustments shou[...]

10 TUNING THE CHASSIS 67 Guideline Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclo ckwise to reduce damping. 10.3 Adjusting the rebound damping of the fork (Duke R) Info The hydraulic rebound damping determin es the fork suspension behavior. 60257[...]

10 TUNING THE CHASSIS 68 Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclo ckwise to reduce damping. 10.4 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-spee d and low-s[...]

10 TUNING THE CHASSIS 69 Info The high-speed setting takes effect during the fast compression of the shock absorber . 602573-10 – Turn adjusting screw 1 all the way clockwise with a socket wrench. Info Do not loosen fitting 2 ! – Turn back counterclockwise by the number of turns correspondin g to the shock absorber type. Guideline Compression d[...]

10 TUNING THE CHASSIS 70 Info The low-speed setting takes effect during the slow to normal compression of the shock absorber. 602573-11 – Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting 2 ! – Turn back counterclockwise by the number of clicks correspond ing to the shock absorber t[...]

10 TUNING THE CHASSIS 71 602574-10 – Turn adjusting screw 1 clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks correspond ing to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; tur[...]

10 TUNING THE CHASSIS 72 – Remove the main silencer. x – Remove the shock absorber. x B00936-10 Main work (Duke) – Adjust the spring preload by turning adjustment unit 1 . Guideline Spring preload Standard 4 clicks Hook wrench (T106S) Info The spring preload can be set to 10 different positions. 602558-10 (Duke R) – Release retaining ring 1[...]

10 TUNING THE CHASSIS 73 Finishing work (Duke R) – Install the shock absorber. x – Install the main silencer. x – Remove the motorcycle from the work stand. 10.9 Adjusting the footrests C00329-10 – Remove lock ring 1 . – Remove the pin of the rider's footrest. Take off the rider's footrest with the spring. C00330-10 – Remove s[...]

10 TUNING THE CHASSIS 74 C00331-01 – Adjust the footrest bracket to the desired position. C00330-10 – Mount and tighten screws 2 . Guideline Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) Loctite ® 243™ C00332-01 – Mount the rider's footrest with the spring and pin.[...]

10 TUNING THE CHASSIS 75 C00329-10 – Mount lock ring 1 . – Repeat the operations on the opposite side.[...]

11 SERVICE WORK ON THE CHASSIS 76 11.1 Raising the motorcycle with the rear wheel stand Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. 602544-01 – Mount the support of the wheel stand. – Insert the adapter in the rear wheel stand. Adapter (61029055120) Rear wheel[...]

11 SERVICE WORK ON THE CHASSIS 77 C00312-11 – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand. 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. P[...]

11 SERVICE WORK ON THE CHASSIS 78 – Raise the front of the motorcycle. 11.4 Taking the motorcycle off of the front wheel stand Note Danger of damage   The parked vehicle may roll 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 Remo[...]

11 SERVICE WORK ON THE CHASSIS 79 11.6 Mounting the passenger seat B00940-10 – Hook catches 1 of the passenger seat onto the storage compartment, lower the rear, and simultaneously push forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents   The passenge r seat can come loose from the anchoring if it[...]

11 SERVICE WORK ON THE CHASSIS 80 11.8 Mounting the passenger seat cover (Duke R) Warning Danger of accidents   Acciden t risk caused by the presence of a passenger. – If the passenger seat cover is mounted, the vehicle is not suitable for transporting a passenger. Do not ride with a passenger. 602560-10 – Hook catches 1 of the passenger seat[...]

11 SERVICE WORK ON THE CHASSIS 81 11.10 Cleaning the chain Warning Danger of accidents   Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents   Reduced brak ing efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and gr[...]

11 SERVICE WORK ON THE CHASSIS 82 11.11 Checking the chain tension Warning Danger of accidents   Danger cause d by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from prematu[...]

11 SERVICE WORK ON THE CHASSIS 83 11.12 Adjusting the chain tension Warning Danger of accidents   Danger cause d by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premat[...]

11 SERVICE WORK ON THE CHASSIS 84 C00314-10 Main work – Loosen nut 1 . – Loosen nuts 2 . – Adjust the chain tension by turning adjusting screws 3 on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws 3 so that the markings on the left and right chain adjusters 4 are in the same position relative[...]

11 SERVICE WORK ON THE CHASSIS 85 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: – Replace the rear sprocket or engine sprocket. x Info The engine sprocket, rear sprocket and chain should always be replaced togeth[...]

11 SERVICE WORK ON THE CHASSIS 86 700152-01 – Shift gear to neutral. – Pull the lower chain section with specified weight A . Guideline Weight of chain wear measurement 15 kg (33 lb.) – Measure the distance B of 18 chain links in the lower chain section. Info Chain wear is not always even. Repeat this measurement at different chain posi- tion[...]

11 SERVICE WORK ON THE CHASSIS 87 B00942-10 – Check the chain sliding guard for wear. » If drill hole D becomes visible on the chain sliding guard in area C : – Replace the chain sliding guard. x – Check that the chain sliding guard is firmly seated. » If the chain sliding guard is loose: – Tighten the chain sliding guard. Guideline Screw[...]

11 SERVICE WORK ON THE CHASSIS 88 11.15 Checking/re ctifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. Do not use brake fluid. B00944-10 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1 . – Remove cover 2 with membra[...]

12 BRAKE SYSTEM 89 12.1 ABS/antilock brake system 0 0 4 4 0 0 3 3 0 0 2 2 0 0 2 2 0 0 1 1 401417-10 The ABS unit 1 , which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor 2 is located at the front and rear wheels. Warning Danger of accidents   Function al limitations of the ABS ?[...]

12 BRAKE SYSTEM 90 ABS warning lamp 3 must light up after the ignition is switched on and go out after start- ing off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake system itself stays fu[...]

12 BRAKE SYSTEM 91 602552-11 (Duke R) – Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel 1 . Info Pull the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding. 12.3 Checking the brake discs Warning Danger of accidents   Reduced brak ing efficiency due to w[...]

12 BRAKE SYSTEM 92 – Replace the brake disc. – Check the front and rear brake discs for damage, cracks, and deformation. » If damage, cracks, or deformation are visible on the brake disc: – Replace the brake disc. 12.4 Checking the brake fluid level of the front brake Warning Danger of accidents   Brake system failur e. – If the brake fl[...]

12 BRAKE SYSTEM 93 602575-10 (Duke R) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in the viewer. » If the brake fluid has dropped below marking A : – Add front brake fluid. x ( p. 93) 12.5 Adding front brake fluid x Warning Danger of accidents   Brake system failur e. ?[...]

12 BRAKE SYSTEM 94 Warning Environmental hazard   Hazardous substances caus e environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulatio ns. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for [...]

12 BRAKE SYSTEM 95 602576-10 (Duke R) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1 . – Remove cover 2 with membrane 3 . – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( p. 183) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overfl[...]

12 BRAKE SYSTEM 96 602583-10 (Duke) – Check the brake linings for minimum thickness A . Minimum thickness A ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickness is less than specified: – Change the front brake linings. x – Check the brake linings for damage and cracking. » If there is damage or cracking: – Change the front brake linings. x [...]

12 BRAKE SYSTEM 97 C00316-10 (Duke) – Disconnect spring 1 . – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A . Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) » If the free travel does not equal the specification: – Adjust the basic [...]

12 BRAKE SYSTEM 98 C00317-10 (Duke) – Disconnect spring 1 . – Remove screw 6 . – Loosen nut 4 and turn it back with ball joint 5 until the maximum amount of free travel is reached. – To adjust the basic position of the foot brake lever to individual requirements, loosen nut 2 and turn screw 3 accordingly. Info The range of adjustment is lim[...]

12 BRAKE SYSTEM 99 602581-10 (Duke R) – Disconnect spring 1 . – Loosen nut 2 and screw in push rod 3 until you have maximum free travel. 602582-10 – To adjust the basic position of the foot brake lever to individual requirements, loosen nut 4 and turn screw 5 accordingly. Info The range of adjustment is limited. – Turn push rod 3 accordingl[...]

12 BRAKE SYSTEM 100 602581-10 – Hold push rod 3 and tighten nut 2 . Guideline Nut, push rod, foot brake lever M6 6 Nm (4.4 lbf ft) – Attach spring 1 . 12.9 Checking rear brake fluid level Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake syst[...]

12 BRAKE SYSTEM 101 B00951-10 – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking 1 : – Add rear brake fluid. x ( p. 101) 12.10 Adding rear brake fluid x Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the M[...]

12 BRAKE SYSTEM 102 Warning Environmental hazard   Hazardous substances caus e environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulatio ns. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for[...]

12 BRAKE SYSTEM 103 12.11 Checking the rear brake linings Warning Danger of accidents   Reduced brak ing efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your author ized KTM workshop will be glad to help.) Note Danger of accidents   Reduced brak ing efficiency caused by damaged brake discs. – If the brake [...]

13 WHEELS, TIRES 104 13.1 Removing the front wheel x Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 76) – Raise the motorcycle with the front wheel stand. ( p. 77) 602545-10 Main work (Duke) – Remove screw 1 and pull wheel speed sensor 2 out of the hole. – Remove screws 3 and spacers 4 . – Press back the brake lin[...]

13 WHEELS, TIRES 105 602546-10 – Loosen screws 5 and 6 . – Unscrew screw 5 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw 5 . Warning Danger of accidents   Reduced brak ing effect caused by damaged brake discs. – Always lay the wheel down in such a way that the brake discs are [...]

13 WHEELS, TIRES 106 602548-10 – Clean screw 1 and wheel spindle 2 . – Lift the front wheel into the fork, position it, and insert the wheel spindle. The arrow on the spoke points in the direction of motion. – Mount and tighten screw 1 . Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) 602545-11 (Duke) – Insert wheel speed s[...]

13 WHEELS, TIRES 107 602562-11 (Duke R) – Insert wheel speed sensor 3 into the hole. Mount and tighten screw 4 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake caliper and check that the brake linings are seated correctly. – Position spacers 5 . Mount screws 6 but do not tighten yet. – Operate the hand brake [...]

13 WHEELS, TIRES 108 13.3 Removing the rear wheel x Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 76) 602563-10 Main work – Remove screw 1 and pull wheel speed sensor 2 out of the hole. – Remove nut 3 . Remove chain adjuster 4 . 602564-10 – Pull out wheel spindle 5 to the point where the chain adjuster is no longer[...]

13 WHEELS, TIRES 109 602565-01 – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. – Withdraw 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 accidents   Reduced brak ing efficiency due to damaged brake [...]

13 WHEELS, TIRES 110 602566-10 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. x – Remove bushing 1 . Clean and grease the mating surfaces of the bushings and the shaft seal rings. Long-life grease ( p. 188) – Install the bushing. – Clean and grease the thread of the [...]

13 WHEELS, TIRES 111 602567-10 – Engage the counter bearing of the brake caliper support A and swingarm. Carefully lift the rear wheel into the swingarm and engage the brake disc. Lay the chain on the rear sprocket and mount the wheel spindle. – Mount chain adjuster 2 and nut 3 . Info Mount the left and right chain adjusters in the same positio[...]

13 WHEELS, TIRES 112 13.5 Checking the rear hub rubber dampers x Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. Preparatory work – Raise the moto[...]

13 WHEELS, TIRES 113 – Change all rubber dampers in the rear hub. Finishing work – Install the rear wheel. x ( p. 109) – Take the motorcycle off of the rear wheel stand. ( p. 76) – Check the chain tension. ( p. 82) 13.6 Checking the tire condition Warning Danger of accidents   Uncontr ollable vehicle handling in the event of a flat tire. [...]

13 WHEELS, TIRES 114 Info The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle. Worn tires have a negative effect on riding behavior, especially on wet surfaces. 400602-10 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tires exhibit cuts, run-in o[...]

13 WHEELS, TIRES 115 13.7 Checking the tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximu m 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 p[...]

14 ELECTRIC AL SYSTEM 116 14.1 Removing the battery x Warning Risk o f injury   Battery acid and battery gases cause serious chemical burns . – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles . – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open flam[...]

14 ELECTRIC AL SYSTEM 117 B00963-10 – Remove positive terminal cover 2 . – Disconnect the positive cable 3 of the battery. – Detach rubber band 4 . – Pull the battery up and out of the battery holder. 14.2 Installing the battery x B00963-11 Main work – Position the battery in the battery holder. Info The terminals of the battery must face[...]

14 ELECTRIC AL SYSTEM 118 B00962-11 – Connect the negative cable 4 of the battery. Guideline Screw, battery terminal M6 2 Nm (1.5 lbf ft) Finishing work – Mount the passenger seat. ( p. 79) – Set the clock. ( p. 35) 14.3 Recharging the battery x Warning Risk o f injury   Battery acid and battery gases cause serious chemical burns . – Keep[...]

14 ELECTRIC AL SYSTEM 119 Warning Environmental hazard   Hazardous substances caus e environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulatio ns. Info Even when there is no load on the battery, it discharges steadily. The charge state and the type of charge are [...]

14 ELECTRIC AL SYSTEM 120 B00964-10 Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000 ) You can also use the battery charger to test the rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never re[...]

14 ELECTRIC AL SYSTEM 121 14.4 Changing the main fuse Warning Fire ha zard   The electrical system can be overloade d if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. The main fuse is under the passenger seat. Preparatory wo[...]

14 ELECTRIC AL SYSTEM 122 602588-10 – Remove the faulty main fuse 2 . Info A defective fuse is indicated by a burned-out fuse wire A . A reserve fuse 3 is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p. 174) Tip Insert a new replacement fuse into the starter relay to have it available when needed. 602587-10 – [...]

14 ELECTRIC AL SYSTEM 123 14.5 Changing the ABS fuses Warning Fire ha zard   The electrical system can be overloade d if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic un[...]

14 ELECTRIC AL SYSTEM 124 B00966-11 To cha nge th e fuse of the ABS return pump: – Take off the protection cover and remove fuse 2 . – Insert a new fuse. Fuse (58011109125) ( p. 174) – Mount the protection cover. Finishing work – Mount the passenger seat. ( p. 79) 14.6 Changing the fuses of individual power consumers Info The fuse box conta[...]

14 ELECTRIC AL SYSTEM 125 B00968-10 – Open fuse box cover 3 . B00969-01 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrumen t, clock, EFI control unit, alarm sys- tem (optional) Fuse 2 - 10 A - ignition, combination instrumen t, EFI control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 1[...]

14 ELECTRIC AL SYSTEM 126 Warning Fire ha zard   The electrical system can be overloade d if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 174) Fuse (75011088015) ( p. 174) Tip Replace the spare fuse in the fuse bo[...]

14 ELECTRIC AL SYSTEM 127 14.7 Removing the headlight mask with the headlight Preparatory work – Switch off all power consumers and switch off the engine. B00972-10 Main work (Duke) – Remove screws 1 . 602577-10 (Duke R) – Remove screws 1 .[...]

14 ELECTRIC AL SYSTEM 128 602578-11 – Fold the headlight mask forward. – Disconnect plug 2 . – Set down the headlight mask. 14.8 Refitting the headlight mask with the headlight 602578-10 Main work – Plug in connector 1 .[...]

14 ELECTRIC AL SYSTEM 129 B00972-11 (Duke) – Position the headlight mask. – Mount and tighten screws 2 . Guideline Screw, headlight EJOT 2 Nm (1.5 lbf ft) Remaining screws, chassis M5 5 Nm (3.7 lbf ft) – Check that the lighting is functioning properly. 602577-11 (Duke R) – Position the headlight mask. – Mount and tighten screws 2 . Guidel[...]

14 ELECTRIC AL SYSTEM 130 Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 127) B00973-10 Main work – Disconnect connector 1 . – Take off protection cap 2 . B00974-10 – Detach retaining clamp 3 . – Remove bulb 4 . – Position the new bulb in the headlight [...]

14 ELECTRIC AL SYSTEM 131 B00973-10 – Mount protection cap 2 . – Plug in connector 1 . Finishing work – Refit the headlight mask with the headlight. ( p. 128) – Check the headlight setting. ( p. 133) 14.10 Changing the parking light bulb Note Damage to reflector   Reduce d brightness. – Grease on the lamp will evaporate due to the heat [...]

14 ELECTRIC AL SYSTEM 132 B00975-10 Main work – Pull cable sleeve 1 and the socket of parking light 2 carefully out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W / socket W2.1x9.5d) ( p. 174) – Carefully position socket 2 with the bulb in the housing. – Mount cable sleeve 1 . Finishing wo[...]

14 ELECTRIC AL SYSTEM 133 B00981-10 – Remove the screw on the rear of the turn signal housing. – Remove turn signal glass 1 . – Press the bulb carefully into the socket, turn it counterclockwise by about 30°, and pull it out of the socket. Info Do not touch the reflector with your fingers, and keep it free from grease. – Press the new bulb[...]

14 ELECTRIC AL SYSTEM 134 – Check the headlight setting. The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 134) 1[...]

15 COOLING SYSTE M 135 15.1 Cooling system B00980-10 The water pump 1 in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radi- ator cap 2 . The heat expansion causes the surplus coolant to flow into the compensating tank 3 . When the temperature falls, this surplus coolant[...]

15 COOLING SYSTE M 136 Warning Danger of poisoning   Coolant is poisonou s and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediatel [...]

15 COOLING SYSTE M 137 » If there is no coolant in the compensating tank: – Check the cooling system for leaks. x Info Do not start up the motorcycle! – Fill/bleed the cooling system. x ( p. 140) – Mount cap 2 of the compensating tank. – Check the coolant level in the radiator. The radiator must be completely filled. » If the coolant leve[...]

15 COOLING SYSTE M 138 Warning Danger of poisoning   Coolant is poisonou s and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediatel [...]

15 COOLING SYSTE M 139 Info Do not start up the motorcycle! – Fill/bleed the cooling system. x ( p. 140) 15.4 Draining the coolant x Warning Danger of scalding   During motorcy cle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is [...]

15 COOLING SYSTE M 140 B00984-10 – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw 1 . Remove the radiator cap. – Completely drain the coolant. – Mount screw 1 with a new seal ring and tighten it. Guideline Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) 15.5 Filling/bleedin g the cooli[...]

15 COOLING SYSTE M 141 B00985-10 – Remove bleeder screw 2 . – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw 2 immediately. Alternative 1 Coolant ( p. 183) Alternative 2 Coolant (mixed ready to use) ( p. 183) – Fill the radiator completely[...]

16 TUNING THE ENGINE 142 16.1 Setting the engine characteristics Preparatory work – Switch off the ignition by turning the ignition key to the position . – Remove the passenger seat. ( p. 78) B00966-12 Main work – Pull off the Map ‑ Select switch with holder 1 from the retaining bracket. – Pull the Map ‑ Select switch out of the holder.[...]

16 TUNING THE ENGINE 143 16.2 Checking the basic position of the shift lever 0 0 0 A A 400692-10 – Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot 10… 20 mm (0.39… 0.79 in) » If the distance does not meet specificat[...]

16 TUNING THE ENGINE 144 B00997-10 – Clean gear teeth A of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gear- ing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure. – Mount an[...]

16 TUNING THE ENGINE 145 – Tighten nut 1 , holding the threaded rod 2 . Guideline Shift rods, nut M6LH 6 Nm (4.4 lbf ft)[...]

17 SERVICE WORK ON THE ENGINE 146 17.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. Condition The engine is at operating temperature. 602585-10 – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one min[...]

17 SERVICE WORK ON THE ENGINE 147 Info Drain the engine oil only when the engine is warm. B00987-10 Main work – Stand the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove the oil drain plug 1 with the magnet and seal ring. – Completely drain the engine oil. – Thoroughly clean th[...]

17 SERVICE WORK ON THE ENGINE 148 B00990-10 – Remove screws 5 . Remove the oil filter cover 6 with the O-ring. – Pull oil filter 7 out of the oil filter housing. Circlip pliers reverse (51012011000 ) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. B00991-10 – Insert the oil filter. – Oil the O-rings of [...]

17 SERVICE WORK ON THE ENGINE 149 B00993-10 – Remove screw plug bk with oil screen bl and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. B01002-10 – Position the oil screen with the O-rings. – Mount and tighten screw plug 8 with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm [...]

17 SERVICE WORK ON THE ENGINE 150 Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. B00995-10 – Remove the oil filler plug bm with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 1[...]

17 SERVICE WORK ON THE ENGINE 151 17.3 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. B00995-11 Main work – Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 10W/60) (00062010035) ( p. 184) Engine oil (SAE 10W/50) ( p. 1[...]

18 CLEANING , CARE 152 18.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressur e cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connec tors, cables, bearings, etc. Maintain a minimum distance of 60 cm betwee[...]

18 CLEANING , CARE 153 – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the closure of the exhaust system. Warning Danger of accidents   Reduced brak ing efficiency due to a wet or dirty brake sys- tem. – Clean or dry a dirty or wet brake system by riding and braking gently. – After cleanin[...]

18 CLEANING , CARE 154 18.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects[...]

19 STORAGE 155 19.1 Storage Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessa ry, you should do this during the storage period (less workshop overload). In this way, you can avoid long worksh[...]

19 STORAGE 156 – Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escapin g, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion conde nses and causes valves and exhaust[...]

20 TROUBLE SHOOTING 157 Faults Possible cause Action Engine does not crank when the elec- tric starter button is pressed Operating error – Carry out the start procedure. ( p. 52) Battery is discharged – Recharge the battery. x ( p. 118) Fuse 1 , 2 or 3 blown – Change the fuses of individual power consumers. ( p. 124) Main fuse burned out – [...]

20 TROUBLE SHOOTING 158 Faults Possible cause Action Engine overheats Too little coolant in cooling system – Check the cooling system for leakage. – Check the coolant level in the compensating tank. ( p. 137) Radiator fins very dirty – Clean radiator fins. Foam formation in cooling system – Drain the coolant. x ( p. 139) – Fill/bleed the [...]

20 TROUBLE SHOOTING 159 Faults Possible cause Action High oil consumption Engine oil level too high – Check the engine oil level. ( p. 146) Engine oil too thin (low viscosity) – Change the engine oil and filter, clean the oil screens. x ( p. 146) Headlight and parking light are not functioning Fuse 6 blown – Cha nge the fuses of individual po[...]

21 BLINK CODE 160 Blink code of FI warning lamp (MIL) 02 FI warning lamp ( MIL ) flashes 2x short Error le vel co ndition Crankshaft position sensor - circuit fault Blink code of FI warning lamp (MIL) 09 FI warning lamp ( MIL ) flashes 9x short Error le vel co ndition Manifold absolute pressure sensor cylin der 1 - input signal too low Manifold abs[...]

21 BLINK CODE 161 Blink code of FI warning lamp (MIL) 15 FI warning lamp ( MIL ) flashes 1x long, 5x short Error le vel co ndition Rollover sensor - input signal too low Rollover sensor - input signal too high Blink code of FI warning lamp (MIL) 17 FI warning lamp ( MIL ) flashes 1x long, 7x short Error le vel co ndition Lambda sensor cylinder 1, s[...]

21 BLINK CODE 162 Blink code of FI warning lamp (MIL) 27 FI warning lamp ( MIL ) flashes 2x long, 7x short Error le vel co ndition SVCC circuit - tracking error Blink code of FI warning lamp (MIL) 33 FI warning lamp ( MIL ) flashes 3x long, 3x short Error le vel co ndition Injector cylinder 1 - circuit fault Blink code of FI warning lamp (MIL) 37 F[...]

21 BLINK CODE 163 Blink code of FI warning lamp (MIL) 45 FI warning lamp ( MIL ) flashes 4x long, 5x short Error le vel co ndition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code of FI warning lamp (MIL) 65 FI warning lamp ( MIL ) flashe[...]

21 BLINK CODE 164 Blink code of FI warning lamp (MIL) 85 FI warning lamp ( MIL ) flashes 8x long, 5x short Error le vel co ndition Accelerator position sensor circuit A - input signal too low Accelerator position sensor circuit A - input signal too high Blink code of FI warning lamp (MIL) 86 FI warning lamp ( MIL ) flashes 8x long, 6x short Error l[...]

21 BLINK CODE 165 Blink code of FI warning lamp (MIL) 90 FI warning lamp ( MIL ) flashes 9x long Error le vel co ndition DBW throttle actuator control internal motor - stuck in inactive DBW throttle actuator control internal motor - stuck in active Blink code of FI warning lamp (MIL) 92 FI warning lamp ( MIL ) flashes 9x long, 2x short Error le vel[...]

21 BLINK CODE 166 Blink code of FI warning lamp (MIL) 96 FI warning lamp ( MIL ) flashes 9x long, 6x short Error le vel co ndition System voltage - input signal too low System voltage - input signal too high[...]

22 TECHNICA L DATA 167 22.1 engine Design 1-cylinder 4-stroke engine, water-co oled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.6:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in) Valve play, cold [...]

22 TECHNICA L DATA 168 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electro nic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug Inside spark plug NGK LKAR8BI-9 Outside spark plug NGK LMAR7A-9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cool[...]

22 TECHNICA L DATA 169 Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) – Screw, oil pump cover, top M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Chain securing guide M6 5 Nm (3.7 lbf ft) – Cylinder head screw M6x25 10 Nm (7.4 lbf ft) Loctite ® 243™ Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Remaining screws, engine M6 10 Nm (7[...]

22 TECHNICA L DATA 170 Screw, stator M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, thermostat case M6x20 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain guide rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover M6 10 Nm (7.4 lbf ft) – Screw, wa[...]

22 TECHNICA L DATA 171 Screw, unlocking of timing chain ten- sioner M10x1 10 Nm (7.4 lbf ft) – Spark plug outside M10x1 11 Nm (8.1 lbf ft) – Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor on cylinder head M12x1.5 12 Nm (8.9 lbf ft) – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Oil pressure regulat[...]

22 TECHNICA L DATA 172 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 183) Coolant (mixed ready to use) ( p. 183) 22.3.3 Fuel Total fuel tank capacity, approx. 14 l (3.7 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 185) 22.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powde r- coated Fork (Duke) WP Sus pension U[...]

22 TECHNICA L DATA 173 Brake discs - diameter Front 320 mm (12.6 in) Rear 240 mm (9.45 in) Brake discs - wear limit Front 4.2 mm (0.165 in) Rear 4.5 mm (0.177 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Secondary drive ratio 16:[...]

22 TECHNICA L DATA 174 Battery CBTX9-BS Battery voltage: 12 V Nominal capacity: 8 Ah Maintenance-free Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 22.5 Electrical system Headlight H4 / socket P43t 12 V 60/55 W Parking light W5W / socket W2.1x9.5d 12 V 5 W Instrument lights and indicat[...]

22 TECHNICA L DATA 175 22.6 Tires Front tires Rear ti res 120/70 ZR 17 M/C 58W TL Michelin Pilot Power 160/60 ZR 17 M/C 69W TL Michelin Pilot Power Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 Duke Fork part number 05.18.7L.19 Fork WP Sus pension Up Side Down 4357 ROMA Spring rate Medium (sta[...]

22 TECHNICA L DATA 176 Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring length with preload spacer(s) 303 mm (11.93 in) Spring rate Medium (standard) 6.5 N/mm (37.1 lb/in) Air chamber length 80±20 mm (3.15±0.79 in) Fork length 831 mm (32.72 in) Fork oil per fork leg 534 ml (18.[...]

22 TECHNICA L DATA 177 22.8.2 Duke R Shock absorber part number 15.18.7M.11 Shock absorber WP Sus pension 4618 with Pro ‑ Lever deflector Compression damping, high-s peed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-sp eed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks R[...]

22 TECHNICA L DATA 178 Soft 70 N/mm (400 lb/in) Medium (standard) 75 N/mm (428 lb/in) Spring length 185 mm (7.28 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Riding sag 60… 65 mm (2.36… 2.56 in) Fitted length 370 mm (14.57 in) Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 185) 22.9 Chassis tightening torque[...]

22 TECHNICA L DATA 179 Screw, plastic clamp of brake line on fork leg M5 2 Nm (1.5 lbf ft) – Screw, pressure regulator M5 4 Nm (3 lbf ft) – Bolt, headlight mask M6 6.3 Nm (4.65 lbf ft) Loctite ® 243™ Chain guard M6 4 Nm (3 lbf ft) Loctite ® 243™ Double-sided grub screw M6 6 Nm (4.4 lbf ft) Loctite ® 243™ Nut, push rod, foot brake lever[...]

22 TECHNICA L DATA 180 Shift rods, nut M6LH 6 Nm (4.4 lbf ft) – Main silencer holder (Duke R) M8x40 25 Nm (18.4 lbf ft) – Main silencer holder (Duke R) M8x60 25 Nm (18.4 lbf ft) – Nut, manifold on cylinder head M8 20 Nm (14.8 lbf ft) Copper paste Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite ® 2701 Remaining nuts, chassis M8 25 Nm [...]

22 TECHNICA L DATA 181 Screw, linkage bracket, front engine fix- ing arm M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, main silencer clamp (Duke R) M8 15 Nm (11.1 lbf ft) – Screw, main silencer fixation M8 25 Nm (18.4 lbf ft) – Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loc[...]

22 TECHNICA L DATA 182 Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Screw, steering head M20x1.5 40 Nm (29.5 lbf ft) – Adjusting ring of swingarm bearing M24x 1.5 25 Nm (18.4 lbf ft) – Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – Nut, steering head M28x1 12 Nm (8.9 lb[...]

23 SUBSTAN CES 183 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standard (see specification s on the container) and that possesses the correspond- ing properties. KTM recommends Castro l and Motorex ® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® ?[...]

23 SUBSTAN CES 184 Engine oil (SAE 10W/60) (00062010035) According to – JASO T903 MA ( p. 189) – SAE ( p. 189) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specification s on the container) and that possess the corresponding properties. KTM recommends Moto rex ® products. Synth[...]

23 SUBSTAN CES 185 Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 189) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corres ponding proper- ties. Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with[...]

23 SUBSTAN CES 186 Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).[...]

24 AUXILIAR Y SUBSTANCES 187 Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ® prod[...]

24 AUXILIAR Y SUBSTANCES 188 Long-life grease Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Bike G rease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline ?[...]

25 STANDAR DS 189 JASO T903 MA Different technical developme nt directions required a new specification for 4-stroke motorcy cles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles becau se there was no separate motorcycle specification. Whereas long service intervals are demanded f[...]

INDEX 190 INDEX A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Antilock brake system . . . . . . . . . . . . . . . . . . . . . [...]

INDEX 191 kilometers or miles, setting . . . . . . . . . . . . . . . . . . . . . . 34 ODO display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 speed display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 tachometer . . . . .[...]

INDEX 192 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Fuse individual power consumers, chang ing . . . . . . . . . . . . . . 124 Fuses, ABS changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 basic po[...]

INDEX 193 Passenger seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Passenger seat cover mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 removing . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

INDEX 194 tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Tire ai r press ure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Tire co ndition checking . . . . . . . . . . . . . . . . . . . . .[...]

*32119 53en* 3211953en 09/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]