Instruction/ maintenance manual of the product 690 KTM
Go to page of 165
OWNER'S MANUAL 2008 690 b SUPERMOTO 690 b SUPERMOTO b R ART. NO. 3211244en.
.
DEAR KTM CUSTOMER 1 '($5 .70 &86720(5 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.
DEAR KTM CUSTOMER 2 © 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
CONTENTS 3 &217(176 MEANS OF REPRESENTATION ........................................ ....... 6 IMPORTANT NOTES ............................................. .................. 7 VIEW OF VEHICLE ................................................ ....
CONTENTS 4 Refueling .................................................................. ....... 51 GREASING AND SERVICE TABLE .......................................... 53 Important maintenance work to be carried out by an authorized KTM workshop. ...
CONTENTS 5 Changing the parking lamp ....................................... ....... 102 Changing flasher bulb .................................... ................. 103 Checking headlamp setting.............................................. 104 Adjusting the headlight range .
MEANS OF REPRESENTATION 6 0($16 2) 5(35(6(17$7,21 Symbols used The symbols used are explained in the following. 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).
IMPORTANT NOTES 7 ,03257$17 127(6 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.
IMPORTANT NOTES 8 Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
IMPORTANT NOTES 9 Warning notes In your own interest, read the specified warning notes. Info Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.
IMPORTANT NOTES 10 ದ The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
11.
VIEW OF VEHICLE 12 9,(: 2) 9(+,&/( View of vehicle, front left side 100187-10.
VIEW OF VEHICLE 13 1 Combination instrument 2 Rear mirror 3 Clutch lever 4 Seat 5 Handrail 6 Front brake caliper 7 Left fuel tap 8 Shift lever 9 Engine number 10 Side stand.
VIEW OF VEHICLE 14 View of vehicle, rear right side 100188-10.
VIEW OF VEHICLE 15 1 Seat lock 2 Light switch, headlight flasher switch, indicator switch, horn 3 Filler cap 4 Emergency OFF switch, electric starter button 5 Hand brake lever 6 Chassis number, type l.
LOCATION OF SERIAL NUMBERS 16 /2&$7,21 2) 6(5,$/ 180%(56 Chassis number/type label 500006-01 The chassis number b is stamped on the steering head on the right. The type label b is located under the chassis number. Key number 100179-10 The key number b can be found on the ist b KEYCODECARD .
LOCATION OF SERIAL NUMBERS 17 Engine number 500001-01 The engine number b is stamped on the left side of the engine under the engine sprocket. Fork part number 100184-10 The fork part number b is stamped on the inner side of the fork stub.
LOCATION OF SERIAL NUMBERS 18 Shock absorber part number 100185-10 The shock absorber part number b is stamped on the top of the shock absorber above the adjusting ring on the engine side.
OPERATING ELEMENTS 19 23(5$7,1* (/(0(176 Clutch lever 100113-10 (690 b SUPERMOTO ) The clutch lever b is fitted on the left side of the handlebar. 100114-10 (690 b SUPERMOTO b R) The clutch lever b is fitted on the left side of the handlebar.
OPERATING ELEMENTS 20 Hand brake lever 500018-01 The hand brake lever b is located on the right side of the handlebar and operates the front wheel brake. The hand brake lever operates the front brake. Light switch 500020-01 The light switch b is fitted on the left side of the handlebar.
OPERATING ELEMENTS 21 Headlight flasher switch 500020-11 The headlight flasher switch b is fitted on the left side of the handlebar. Possible states • Headlight flasher switch in neutral position • Headlight flasher switch pressed ದb In this position, the headlight flasher (high beam) is actuated.
OPERATING ELEMENTS 22 Horn 500021-11 The horn button b is fitted on the left side of the handlebar. Possible states • Horn button b in neutral position • Horn button b pressed ದb The horn is operated in this position.
OPERATING ELEMENTS 23 Emergency OFF switch 500022-10 The emergency OFF switch b is fitted on the left side of the handlebar. Possible states Emergency OFF switch on ದb This position is necessary for operation as the ignition circuit is closed.
OPERATING ELEMENTS 24 Combination instrument 700116-01 The combination instrument is attached in fromt of the handlebar. The combination instrument is divided into 4 function areas.
OPERATING ELEMENTS 25 Combination instrument - tachometer 100118-10 The tachometer b displays the engine speed in revolutions per minute.
OPERATING ELEMENTS 26 Battery warning lamp lights up ದb Voltage in electrical system too low. Combination instrument - Display 700118-01 When you switch on the ignition, all display segments light up for a second as a function test.
OPERATING ELEMENTS 27 Combination instrument - speed display 700114-01 The speed b is displayed in kilometers per hour b km/h or miles per hour b Mph . Setting kilometers or miles Info If you change the unit, the ODO value is retained and converted accordingly.
OPERATING ELEMENTS 28 700120-01 ದ Turn the ignition key to the position b . ದ Press the b MODE b button several times until the b ODO display mode is active. ದ Keep the MODE b button pressed until the display mode changes from b Km/h to Mph or from Mph to Km/h .
OPERATING ELEMENTS 29 700115-01 ದ Turn the ignition key to the position b . ದ Press the b MODE b button several times until the b ODO display mode is active. ದ Keep the b MODE b button and the b SET b button pressed simultaneously. The time begins to flash.
OPERATING ELEMENTS 30 700121-01 ದ Turn the ignition key to the position b . ದ Press the b MODE b button several times until the b TRIP b 1 display mode is active.
OPERATING ELEMENTS 31 Combination instrument - b TRIP b F display 700123-01 When the fuel level reaches the reserve mark, the display automatically changes to b TRIP b F and begins to count from b 0.0 , regardless of which display mode was previously active.
OPERATING ELEMENTS 32 Opening filler cap 500023-10 ದ Lift the cover of the filler cap b and insert the ignition key. ದ Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system.
OPERATING ELEMENTS 33 Fuel taps 100178-10 The fuel taps b are located on the left/right under the fuel tank. Possible states • Fuel supply closed ದb The knurled screws are turned clockwise as far as possible. The level cannot be compensated and no fuel can flow out of the fuel tank.
OPERATING ELEMENTS 34 Seat lock 100108-10 The seat lock b is located to the right of the seat. You can lock it with the ignition key. OWNER'S MANUAL 500031-10 You can find the owner's manual b in its protective case on the underside of the seat.
OPERATING ELEMENTS 35 Tool set 500032-10 The tool set b is located in the storage compartment under the seat. Passenger footrests 500036-10 The passenger footrests b can be folded in and out. Possible states • Passenger footrests folded up ದb For operation without a passenger.
OPERATING ELEMENTS 36 Shift lever 100110-10 The shift lever b is mounted on the left side of the engine. 100111-10 The gear positions can be seen in the photograph.
OPERATING ELEMENTS 37 Foot brake pedal 100183-10 The footbrake pedal b is located in front of the right footrest. The footbrake pedal operates the rear brake. Side stand 500034-10 The side stand b is coupled with the safety electric starter system - see the riding instruc- tions.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 38 *(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21 Advice on first use Danger Danger of accidents ಘ Danger from inadequate traffic experience. ದ Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 39 Info When using your vehicle, remember that others may feel disturbed by excessive noise. ದ Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 40 ದ Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents ಘ Unstable riding behavior.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 41 Warning Danger of accidents ಘ Unstable handling characteristics due to slipped baggage. ದ Check the way your baggage is fixed regularly. Warning Danger of burns ಘ A hot exhaust system can burn baggage.
RIDING INSTRUCTIONS 42 5,',1* ,16758&7,216 Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride.
RIDING INSTRUCTIONS 43 Starting Danger Danger of poisoning ಘ Exhaust gases are poisonous and can result in unconsciousness and/or death. ದ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
RIDING INSTRUCTIONS 44 100109-10 ದ Turn the emergency OFF switch to the b position b . ದ Turn the ignition key to the position b . After switching on the ignition, you can hear the fuel pump working for about 2 seconds. At the same time, the combination instrument runs a function test.
RIDING INSTRUCTIONS 45 Starting up ದ Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents ಘ An abrupt load alterations can cause the vehicle to get out of control.
RIDING INSTRUCTIONS 46 Warning Danger of accidents ಘ Reduced road grip with cold tires. ದ On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents ಘ Reduced road grip with new tires.
RIDING INSTRUCTIONS 47 Note Engine failure ಘ Overheating of engine. ದ 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 radiator, and top up if necessary.
RIDING INSTRUCTIONS 48 ದ For example, if the engine stalls at a junction, just pull the clutch and press the electric starter button. You do not need to shift into neutral. ದ Switch off the engine if you expect to be standing for a long time. ದ If the FI b warning lamp ( MIL ) starts to light up during the journey, stop immediately.
RIDING INSTRUCTIONS 49 Warning Danger of accidents ಘ Longer stopping distance due to higher overall weight. ದ Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents ಘ Delayed brake action on salted roads.
RIDING INSTRUCTIONS 50 ದ Always place the vehicle on a firm and even surface. Note Fire hazard ಘ Some components (engine, radiator and exhaust system) get very hot when the engine is running. ದ Do not place the vehicle where there are flammable or explosive substances.
RIDING INSTRUCTIONS 51 Refueling Danger Fire hazard ಘ Fuel can easily catch fire. ದ Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
RIDING INSTRUCTIONS 52 100120-10 ದ Switch off engine. ದ Open the filler cap. ( P. 32) ದ Fill the fuel tank with fuel up to measurement b . Specification Measurement of b 50 b mm (1.97 b in) Fuel tank content 13.5 b l (3.57 b US b gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P.
GREASING AND SERVICE TABLE 53 *5($6,1* $1' 6(59,&( 7$%/( Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A J1A J2A Engine Change engine oil and oil filter, clean oil screens. b x ( P. 118) ••••• Check and adjust valve clearance.
GREASING AND SERVICE TABLE 54 K10N K50A K100A J1A J2A Attachments Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • • Brakes Check the front brake linings. ( P. 75) • • • • • Check the rear brake linings.
GREASING AND SERVICE TABLE 55 K10N K50A K100A J1A J2A Wheels Check the chain wear. ( P. 69) • • • • • Check rear sprocket / engine sprocket for tightness. • • • • • Check rear sprocket / engine sprocket for wear. ( P. 68) • • • • • Check the chain tension.
MAINTENANCE WORK ON CHASSIS AND ENGINE 56 0$,17(1$1&( :25. 21 &+$66,6 $1' (1*,1( Jacking up front of motorcycle Note Danger of damage ಘ Danger of damage by the vehicle running away or falling over. ದ Always place the vehicle on a firm and even surface.
MAINTENANCE WORK ON CHASSIS AND ENGINE 57 Jacking up rear of motorcycle Note Danger of damage ಘ Danger of damage by the vehicle running away or falling over. ದ Always place the vehicle on a firm and even surface. 500095-01 ದ Insert the work stand adapter in the work stand and screw it into the link forks.
MAINTENANCE WORK ON CHASSIS AND ENGINE 58 Fork/shock absorber 100177-10 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 b .
MAINTENANCE WORK ON CHASSIS AND ENGINE 59 ದ Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Compression damping Comfort 20 b clicks Standard 15 b clicks Sport 10 b clicks full payload 10 b clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE 60 ದ Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Rebound damping Comfort 20 b clicks Standard 15 b clicks Sport 10 b clicks full payload 10 b clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE 61 100125-10 ದ Turn the adjusting screw b clockwise with a screwdriver until it stops. Info Do not loosen nut b ! ದ Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
MAINTENANCE WORK ON CHASSIS AND ENGINE 62 100126-10 ದ Turn the adjusting screw b clockwise with an open-ended spanner until it stops. Info Do not loosen nut b ! ದ Turn back counterclockwise the number of turns corresponding to the shock absorber type.
MAINTENANCE WORK ON CHASSIS AND ENGINE 63 100127-10 ದ Turn the adjusting screw b clockwise until it stops. ದ Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
MAINTENANCE WORK ON CHASSIS AND ENGINE 64 Checking chain dirt ದ Check the chain for coarse dirt accumulation. » If the chain is very dirty: ದ Clean the chain. ( P. 64) Cleaning the chain Warning Danger of accidents ಘ Oil or grease on the tires reduces their grip.
MAINTENANCE WORK ON CHASSIS AND ENGINE 65 ದ After drying, apply chain spray. Onroad chain spray ( P. 155) Checking the chain tension Warning Danger of accidents ಘ Danger caused by incorrect chain tension.
MAINTENANCE WORK ON CHASSIS AND ENGINE 66 100130-10 ದ Lean the motorcycle on the side stand. ದ Shift gear to neutral. ದ Push the chain upwards near the vertical rib of the swingarm and measure the chain tension b . Info The upper chain section b must be taut.
MAINTENANCE WORK ON CHASSIS AND ENGINE 67 100131-10 ದ Lean the motorcycle on the side stand. ದ Shift gear to neutral. ದ Loosen nut b . ದ Loosen nuts b . ದ Adjust the chain tension by turning the adjusting screws b left and right.
MAINTENANCE WORK ON CHASSIS AND ENGINE 68 Checking rear sprocket / engine sprocket for wear 100132-10 ದ Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: ದ Replace rear sprocket / engine sprocket.
B 1 2 3 1 6 1 7 1 8 A MAINTENANCE WORK ON CHASSIS AND ENGINE 69 Checking chain wear 100133-10 ದ Shift into neutral, pull the lower chain section with the specified weight b . Specification Weight of chain wear measurement 15 b kg (33 b lb.
MAINTENANCE WORK ON CHASSIS AND ENGINE 70 Checking brake discs Warning Danger of accidents ಘ Reduced braking due to worn brake discs. ದ Worn brake discs should be replaced immediately in an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 71 Adjusting basic position of handbrake lever 100117-10 ದ Adjust the basic setting of the handbrake lever to your hand size by turning adjusting wheel b . Info Pull the brake lever forwards and turn the adjusting wheel.
MAINTENANCE WORK ON CHASSIS AND ENGINE 72 100136-10 (690 b SUPERMOTO) ದ The brake fluid level must not fall below the center of the level viewer b when the brake fluid reservoir is vertical. » If the brake fluid level is lower than the center of the level viewer: ದ Top up the brake fluid of the front brake.
MAINTENANCE WORK ON CHASSIS AND ENGINE 73 Warning Skin irritations ಘ Brake fluid can cause skin irritation on contact. ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE 74 100180-10 (690 b SUPERMOTO) ದ Remove screws b . ದ Remove the cover b with membrane b . ದ Top up brake fluid to level b . Specification Measurement of b 5 b mm (0.2 b in) Brake fluid DOT 5.
MAINTENANCE WORK ON CHASSIS AND ENGINE 75 Brake linings The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties.
MAINTENANCE WORK ON CHASSIS AND ENGINE 76 100137-10 ದ Check the brake linings for minimum thickness b . » Minimum thickness b : ุb 1 b mm ( ุb 0.04 b in) If the minimum thickness is less than specified: ದ Worn brake linigs should be replaced immediately in an authorized KTM work- shop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 77 Checking rear brake fluid level Warning Danger of accidents ಘ Brake system failure. ದ MIN If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
MAINTENANCE WORK ON CHASSIS AND ENGINE 78 Warning Skin irritations ಘ Brake fluid can cause skin irritation on contact. ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE 79 100176-10 ದ Stand the vehicle upright. ದ Remove screw cover b with membrane b . ದ Top up the brake fluid to b MAX level. Brake fluid DOT 5.1 ( P. 152) ದ Check parts for damage and wear. Replace damaged or worn parts.
MAINTENANCE WORK ON CHASSIS AND ENGINE 80 100139-10 ದ Check the brake linings for minimum thickness b . » Minimum thickness b : ุb 1 b mm ( ุb 0.04 b in) If the minimum thickness is less than specified: ದ Worn brake linings should be replaced immediately in an authorized KTM work- shop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 81 100141-10 ದ Loosed screw b and screw b . ದ Screw out screw b about 6 turns, press your hand on the screw to push the wheel spin- dle out of the fork stub. Remove screw b . Warning Danger of accidents ಘ Reduced braking due to damaged brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE 82 ದ Position the spacing sleeves b . Mount and tighten screws b . Specification Screw, front brake caliper M10x1.25 45 b Nm (33.2 b lbf b ft) Loctite ® 243™ 100168-10 ದ Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.
MAINTENANCE WORK ON CHASSIS AND ENGINE 83 100145-10 ದ Pull the rear wheel and brake caliper support b together to the rear until you can swing the brake caliper support to the side. Warning Danger of accidents ಘ Reduced braking due to damaged brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE 84 100146-10 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Remove the bushing b . Clean and grease the roll surfaces of the bushing and the shaft seal ring b . Long-life grease ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE 85 Checking the rear hub rubber dampers b 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE 86 Tire condition checking Warning Danger of accidents ಘ Uncontrollable handling behavior caused by a flat tire.
MAINTENANCE WORK ON CHASSIS AND ENGINE 87 100172-10 ದ Examine the tires for cuts, foreign bodies and other damage. ದ Check the depth of the tread. » Info Note local national regulations concerning the minimum tread depth. Minimum tread depth: ุb 2 b mm ( ุb 0.
MAINTENANCE WORK ON CHASSIS AND ENGINE 88 Checking spoke tension (690 b SUPERMOTO) Warning Danger of accidents ಘ Unstable riding behavior due to loose spokes. ದ If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 89 Removing the seat 100108-10 ದ Insert the ignition key in the seat lock b and turn it 45° counterclockwise.
MAINTENANCE WORK ON CHASSIS AND ENGINE 90 Reinstalling the fuel tank ದ Remove the seat. ( P. 89) 100173-10 ದ Remove screw b . Info The fuel lines do not need to be disconnected. 100174-10 ದ Lay a cloth b over the subframe and straighten the steering.
MAINTENANCE WORK ON CHASSIS AND ENGINE 91 Positioning the fuel tank 100174-11 ದ Remove the cloth b from between the compensating tank and the spoiler. 100175-10 ದ Carefully move the fuel tank forwards and lower it. ದ Mount and tighten the screw b with the rubber bushing and bearing sleeve.
MAINTENANCE WORK ON CHASSIS AND ENGINE 92 Removing the battery b x Warning Risk of injury ಘ Battery acid and battery gases cause serious cauterization. ದ Keep batteries out of the reach of children. ದ Wear suitable protective clothing and goggles.
MAINTENANCE WORK ON CHASSIS AND ENGINE 93 Installing the battery b x 100169-11 ದ Push the battery from the right into the battery rack. Info The battery terminals must be at the front. ದ Secure the battery with the rubber band b .
MAINTENANCE WORK ON CHASSIS AND ENGINE 94 Warning Environmental hazard ಘ Problem materials cause environmental damage. ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Even if there is no load on the battery, it loses power every day.
MAINTENANCE WORK ON CHASSIS AND ENGINE 95 100151-10 ದ Connect the battery charger to the battery. Switch on the battery charger. Battery charger b (58429074000 ) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the generator.
MAINTENANCE WORK ON CHASSIS AND ENGINE 96 Info The main fuse protects all power-consuming components of the vehicle. It is located in the housing of the electric starter relay next to the battery. ದ Switch off all power-consuming components and switch off the engine.
MAINTENANCE WORK ON CHASSIS AND ENGINE 97 Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. ದ Switch off all power-consuming components and switch off the engine.
MAINTENANCE WORK ON CHASSIS AND ENGINE 98 100154-10 ದ Remove defective fuse. Specification Fuse b 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse b 2 - 10A - clock, ignition.
MAINTENANCE WORK ON CHASSIS AND ENGINE 99 Warning Fire hazard ಘ The electrical system can be overloaded by the use of incorrect fuses. ದ Use only fuses with the prescribed amperage. Never by-pass or repair fuses. ದ Use spare fuses with the correct rating only.
MAINTENANCE WORK ON CHASSIS AND ENGINE 100 100156-10 ದ Pull the bulb holder of the parking light b out of the headlight housing. ದ Pull the plug-in connector b off the headlight.
MAINTENANCE WORK ON CHASSIS AND ENGINE 101 100155-11 ದ Position the headlight mask. Mount and tighten screws b . Specification Screw, headlight mask M6 5 b Nm (3.7 b lbf b ft) ದ Check lighting function. Changing headlight bulb Note Damage to reflector ಘ Keep the glass of the bulb free of grease.
MAINTENANCE WORK ON CHASSIS AND ENGINE 102 100157-10 ದ Take the rubber cap off the headlight lamp. ದ Turn the bulb holder b about 30° counterclockwise and remove it. ದ Take the headlight bulb out of the headlight housing. ದ Check parts for damage and wear.
MAINTENANCE WORK ON CHASSIS AND ENGINE 103 100161-10 ದ Pull the parking light bulb b out of the holder. ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Insert a new parking light bulb in the holder. Parking light b (W2,1x9,5d ) ( P.
B A MAINTENANCE WORK ON CHASSIS AND ENGINE 104 ದ Press the new flasher bulb carefully into the holder and turn it clockwise as far as it will go. Flasher light b (BAU15s) ( P. 144) ದ Position the diffuser. ದ Insert the screw and turn it first counterclockwise until you feel it click into the thread.
B A MAINTENANCE WORK ON CHASSIS AND ENGINE 105 Adjusting the headlight range 100159-10 ದ On a light-colored wall with a horizontal area in front of it, make a mark as high as the center of the low beam headlight. ದ Make another mark at a distance of b under the first mark.
MAINTENANCE WORK ON CHASSIS AND ENGINE 106 Cooling system 100166-10 The water pump b in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap b .
MAINTENANCE WORK ON CHASSIS AND ENGINE 107 Warning Danger of poisoning ಘ Coolants are poisonous and a health hazard. ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor.
MAINTENANCE WORK ON CHASSIS AND ENGINE 108 100165-10 ದ Screw off the radiator cap b . ದ Check antifreeze of coolant. 25… 45 b °C ( 13… 49 b °F) » If the antifreeze of the cooling liquid does not meet specifications: ದ Correct antifreeze of coolant.
MAINTENANCE WORK ON CHASSIS AND ENGINE 109 Checking the coolant level Warning Danger of scalding ಘ The coolant gets very hot when the motorcycle is driven and is under high pressure. ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot.
MAINTENANCE WORK ON CHASSIS AND ENGINE 110 100165-10 ದ Screw off the radiator cap b and check the coolant level in the radiator. The radiator must be completely full. » If the level of the cooling liquid does not meet specifications: ದ Correct the coolant level and find out the cause of the loss.
MAINTENANCE WORK ON CHASSIS AND ENGINE 111 Warning Danger of poisoning ಘ Coolants are poisonous and a health hazard. ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor.
MAINTENANCE WORK ON CHASSIS AND ENGINE 112 100189-10 ದ Remove the radiator cap b and the bleeder screw b . ದ Tilt the vehicle slightly to the right. 100190-10 ದ Pour coolant in until it overflows free of bubbles, and then replace the bleeder screw immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE 113 100191-10 ದ Switch off the engine and allow it to cool down. ದ After the engine has cooled down, check the coolant level in the radiator again and add more coolant if necessary. ದ Remove the cap of the compensating tank b and top up the coolant level up to the b MAX marking.
MAINTENANCE WORK ON CHASSIS AND ENGINE 114 100116-10 (690 b SUPERMOTO b R) ದ Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw b . Checking/correcting fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc.
MAINTENANCE WORK ON CHASSIS AND ENGINE 115 ದ Position the cover with the membrane. Mount and tighten screws. 100194-10 (690 b SUPERMOTO b R) ದ Check the fluid level. The fluid level must be between the b MIN and b MAX b markings. » If the fluid level does not meet specifications: ದ Remove screw with membrane.
MAINTENANCE WORK ON CHASSIS AND ENGINE 116 Danger Danger of poisoning ಘ Exhaust gases are poisonous and can result in unconsciousness and/or death. ದ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
MAINTENANCE WORK ON CHASSIS AND ENGINE 117 Adjusting the handlebar angle b x 100196-10 ದ Loosen screw b . ದ Move the handlebar to the desired position and slightly tichten the screws. ದ Move the handlebar carefully in both directions as far as it will go.
MAINTENANCE WORK ON CHASSIS AND ENGINE 118 700113-01 Condition The engine is at operating temperature. ದ Check the engine oil level. Info After switching off the engine, wait for one minute and then check. The engine oil must be between the lower and upper edge of the oil level viewer.
MAINTENANCE WORK ON CHASSIS AND ENGINE 119 Info Drain the engine oil only when the engine is warm. ದ Stand the motorcycle on its side stand on a horizontal surface. 700106-01 ದ Place a suitable container under the engine. ದ Remove the oil drain plug b with the magnet and seal ring.
MAINTENANCE WORK ON CHASSIS AND ENGINE 120 Removing the oil filter b x Warning Danger of scalding ಘ Engine oil and gear oil get very hot when the motocycle is driven. ದ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE 121 700104-01 ದ Remove screws b . Remove oil filter cover b with O-ring. ದ Pull the oil filter insert b out of the oil filter casing. Circlip pliers reverse (51012011000 ) ದ Completely drain the engine oil.
MAINTENANCE WORK ON CHASSIS AND ENGINE 122 Warning Environmental hazard ಘ Problem materials cause environmental damage. ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. ದ Place a suitable container under the engine.
MAINTENANCE WORK ON CHASSIS AND ENGINE 123 700111-01 ದ Position oil screen b with O-rings. ದ Refit plug b with O-ring and tighten it. Specification Plug, oil screen M20x1,5 15 b Nm (11.1 b lbf b ft) 700112-01 ದ Position oil screen b with O-rings.
MAINTENANCE WORK ON CHASSIS AND ENGINE 124 700107-01 ದ Remove filler plug with O-ring b from the clutch cover and add engine oil. Engine oil 1.70 b l (1.
MAINTENANCE WORK ON CHASSIS AND ENGINE 125 Danger Danger of poisoning ಘ Exhaust gases are poisonous and can result in unconsciousness and/or death. ದ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
TROUBLESHOOTING 126 7528%/(6+227,1* Faults Possible cause Measure Engine does not turn when the electric starter button is pressed Operating error ದ Carry out the instructions for starting. ( P. 43) Battery discharged ದ Recharge the battery.
TROUBLESHOOTING 127 Faults Possible cause Measure Engine has too little power. Fuel filter very dirty ದ Have the fuel filter changed. Defect in fuel injection system ದ Read the error memory with the KTM diagnostics tool and correct the fault. Engine overheats.
TROUBLESHOOTING 128 Faults Possible cause Measure High oil consumption Engine oil level too high ದ Check the engine oil level. ( P. 117) Engine oil too thin (low viscosity) ದ Change engine oil and oil filter, clean oil screens.
FLASHING CODE 129 )/$6+,1* &2'( Fault Description Possible cause Measure 02 FI b warning lamp ( MIL ) flashes briefly 2x Malfunction in ignition pulse generator circuit ದ Check the ignition pulse generator.
FLASHING CODE 130 Fault Description Possible cause Measure 27 FI b warning lamp ( MIL ) flashes 2x long, 7x short Malfunction in voltage supply circuit of throttle valve control unit ದ Check the throttle valve con- trol unit voltage supply.
FLASHING CODE 131 Fault Description Possible cause Measure 91 FI b warning lamp ( MIL ) flashes 9x long, 1x short Malfunction in CAN bus com- munication ದ Check CAN bus communica- tion.
CLEANING 132 &/($1,1* Cleaning motorcycle Note Material damage ಘ Damage and destruction of components by high-pressure cleaning equipment. ದ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet.
CLEANING 133 Warning Danger of accidents ಘ Reduced braking due to wet or dirty brakes. ದ Clean or dry dirty or wet brakes by riding and braking gently. ದ After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
CONSERVATION FOR WINTER OPERATION 134 &216(59$7,21 )25:,17(5 23(5$7,21 Conservation for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt.
STORAGE 135 6725$*( 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 necessary, you should do this during the storage period (less workshop overload).
STORAGE 136 ದ Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
TECHNICAL DATA - ENGINE 137 7(&+1,&$/ '$7$ (1*,1( Design 1-cyliner 4-stroke engine, water-cooled Displacement 654 b cm³ (39.91 b cu b in) Stroke 80 b mm (3.15 b in) Bore 102 b mm (4.02 b in) Compression ratio 11,8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 b mm (1.
TECHNICAL DATA - ENGINE 138 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Generator 12 b V, 224 b W Spark plug NGK LKAR 8AI - 9 spark plug electrode gap 0.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 139 7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6 Plug, oil bore self-tapping 9 b Nm (6.6 b lbf b ft) Loctite ® 243™ Screw, membrane fixation M3 2.5 b Nm (1.84 b lbf b ft) Loctite ® 243™ Oil jet, conrod lubrication M 4 2 b Nm (1.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 140 Screw, shift drum locating M6 10 b Nm (7.4 b lbf b ft) Loctite ® 243™ Screw, shift lever M6 10 b Nm (7.4 b lbf b ft) Loctite ® 222 Screw, timing chain tensioning rail M6 10 b Nm (7.4 b lbf b ft) Loctite ® 243™ Screw, starter motor M6 10 b Nm (7.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 141 Screw, cylinder head M10 Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 15 b Nm (11.1 b lbf b ft) Step 2 30 b Nm (22.1 b lbf b ft) Step 3 45 b Nm (33.2 b lbf b ft) Step 4 60 b Nm (44.
TECHNICAL DATA - CHASSIS 142 7(&+1,&$/ '$7$ &+$66,6 Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP b Suspension Up Side Down 4860 ROMA Shock absorber WP b Suspension b 4618 with Pro ತ Lever deflector Suspension travel front 210 b mm (8.
TECHNICAL DATA - CHASSIS 143 Rear 2.2 b bar (32 b psi) Rear wheel gearing 16:40 Chain 5/8 b x b 1/4” X ತ ring Steering head angle 63.5 ° Wheelbase 1,472±15 b mm (57.95 ±0.59 b in) Seat height unloaded 880 b mm (34.65 b in) Ground clearance unloaded 245 b mm (9.
TECHNICAL DATA - CHASSIS 144 Flasher light BAU15s 12 b V 10 b W Brake / tail light LED Licence plate lamp W2,1x9,5d 12 b V 5 b W Validity Front tire Rear tire (690 b SUPERMOTO ) 120/70 b R b 17 b 58 b.
TECHNICAL DATA - FORK 145 7(&+1,&$/ '$7$ )25. Fork part number (690 b SUPERMOTO) 14.18.7D.07 Fork part number (690 b SUPERMOTO b R) 14.
TECHNICAL DATA - SHOCK ABSORBER 146 7(&+1,&$/ '$7$ 6+2&. $%625%(5 Shock absorber part number (690 b SUPERMOTO) 15.18.9D.07 Shock absorber part number (690 b SUPERMOTO b R) 15.
TECHNICAL DATA - SHOCK ABSORBER 147 Gas pressure 12 b bar (174 b psi) Static sag 27 b mm (1.06 b in) Riding sag 60… 65 b mm (2.36… 2.56 b in) Fitted length 380 b mm (14.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 148 7(&+1,&$/ '$7$ &+$66,6 7,*+7(1,1* 72548(6 Screw, combination instrument 1 b Nm (0.7 b lbf b ft) ದ Screw, combination instrument holder 1 b Nm (0.7 b lbf b ft) ದ Screw, side stand switch M4 2 b Nm (1.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 149 Screw, front brake disc (690 b SUPER- MOTO) M6 14 b Nm (10.3 b lbf b ft) Loctite ® 243™ Screw, footbrake cylinder M6 10 b Nm (7.4 b lbf b ft) Loctite ® 243™ Screw, horn M 6 6 b Nm (4.4 b lbf b ft) Loctite ® 243™ Screw, license plate holder M 6 8 b Nm (5.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 150 Screw, front brake disc (690 b SUPER- MOTO b R) M8 30 b Nm (22.1 b lbf b ft) Loctite ® 243™ Screw, spring holder on side stand bracket M8 25 b Nm (18.4 b lbf b ft) Loctite ® 243™ Screw, rear footrest clamp M8 25 b Nm (18.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 151 Screw, bottom shock absorber M10 45 b Nm (33.2 b lbf b ft) Loctite ® 243™ Screw, handlebar support M10 20 b Nm (14.8 b lbf b ft) ದ Screw, side stand M10 35 b Nm (25.8 b lbf b ft) Loctite ® 243™ Lambda probe M12x1.
SUBSTANCES 152 68%67$1&(6 Super unleaded (ROZ 95 / RON 95 / PON 91) according to ದ DIN b EN b 228 (ROZ 95 / RON 95 / PON 91) Brake fluid DOT 5.1 according to ದ DOT Specification ದ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties.
SUBSTANCES 153 Hydraulic fluid (15) according to ದ ISO VG (15) Specification ದ Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products.
SUBSTANCES 154 Specification ದ Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding prop- erties.
AUXILIARY SUBSTANCES 155 $8;,/,$5< 68%67$1&(6 Chain cleaner Specification ದ KTM recommends Motorex ® products. Supplier Motorex ದ Motorex ® b Chain b Clean b 611 Onroad chain spray Specification ದ KTM recommends Motorex ® products.
AUXILIARY SUBSTANCES 156 Cleaning and polishing materials for metal, rubber and plastic Specification ದ KTM recommends Motorex ® products. Supplier Motorex ದ Motorex ® b Protect b & b Shine b 645 High-luster polish for paint Specification ದ KTM recommends Motorex ® products.
STANDARDS 157 67$1'$5'6 JASO b T903 b MA Different technical development directions required a new specification for 4-stroke motorcycles ದ the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.
INDEX 158 ,1'(; A Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 B Baggage ......... ......... ........ ........ .... 4 0 Battery fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 159 Conservation for winter operation .... ........ ........ . 1 3 4 Coolant draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Coolant level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 , 109 Cooling system .
INDEX 160 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . . . 71 Handlebar angle adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 161 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Checks before putting into operation . . . . . . . . . . . . . . . . 42 R Rear hub rubber dampers checking . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 162 V View of vehicle front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 rear right side . . . . . . . . . . . .
KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 11/2007 Photo Mitterbauer *3211244 en* 3211244en.
An important point after buying a device KTM 690 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 690 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 690 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 690 you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 690 will certainly help you make a decision on the purchase.
If you already are a holder of KTM 690, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 690.
However, one of the most important roles played by the user manual is to help in solving problems with KTM 690. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 690 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
