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Kenmore 790.9093 Range User Manual

1. 3 30 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 VIEW OF VEHICLE 3 View of vehicle front left side 100187 10 VIEW OF VEHICLE 1 1 1 1 0 0 Combination instrument Rear mirror Clutch lever Seat Handrail Front brake caliper Left fuel tap Shift lever Engine number Side stand WO CO NI dj OT BR Q DN Fe m o View of vehicle rear right side 100188 10 ___VlEW OF VEHICLE 1n 035 Seat lock Light switch headlight flasher switch indicator switch horn Filler cap Emergency OFF switch electric starter button Hand brake lever Chassis number type label Rear brake caliper Passenger footrests WO CO NI Md OT 5 Q N Re Foot brake pedal Engine oil level viewer il pi ax Right fuel tap The chassis number is stamped on the steering head on the right The type label is located under the chassis number 500006 01 The key number can be found on the ist KEYCODECARD You need the key number to order a spare key Keep the KEYCODECARD in a safe place 1 The engine number is stamped on the left side of the engine under the engine sprocket 500001 01 The fork part number
2. Fuse 1 2 or 4 blown Engine vent hose bent Change the fuses of individual power consumers P 97 Route the vent hose without bends or replace it if necessary Faults High oil consumption Possible cause Engine oil level too high Engine oil too thin low viscosity TROUBLESHOOTING gt h sas Measure Check the engine oil level P 117 Change engine oil and oil filter clean oil screens P 118 Headlight and parking light not functioning Fuse 7 blown Change the fuses of individual power consumers P 97 Flasher light brake light and horn not Fuse 6 blown Change the fuses of individual power functioning consumers P 97 Time is not correctly displayed Fuse 2 blown Change the fuses of individual power Battery discharged Ignition not switched off when vehicle was parked consumers P 97 Set the clock P 28 Recharge the battery P 93 Battery is not charged by generator Check charging voltage Combination instrument shows nothing in the display Speedometer in combination instrument not functioning Fuse 1 blown Speedometer cable harness damaged or plug oxidized Change the fuses of individual power consumers P 97 Have the cable harness and plug checked ETC CCT Malfunction in ignition pulse Check the ignition pulse generator circuit generator A Fau
3. e Tip I Replace the spare fuse in the fuse box so that it will be available if needed Close the fuse box cover Mount the seat P 89 Removing headlight mask with headlight Y Remove the 4 screws O and carefully take off the headlight mask MAINTENANCE WORK ON CHASSIS AND ENGINE w Pull the bulb holder of the parking light out of the headlight housing Pull the plug in connector off the headlight Place the headlight mask to one side Connect the plug in connector to the headlight Insert the bulb holder of the parking light into the headlight housing MAINTENANCE WORK ON CHASSIS AND ENGINE oy Position the headlight mask Mount and tighten screws Specification Screw headlight mask 5 Nm 3 7 Ibf ft Check lighting function Changing headlight bulb Note Damage to reflector Keep the glass of the bulb free of grease After fitting the bulb in the holder clean the glass with a clean cloth Any grease on the glass will evaporate by the heat and be de posited on the reflector Switch off all power consuming components and switch off the engine Remove the headlight mask with the headlight P 99 MAINTENANCE WORK ON CHASSIS AND ENGINE h 0 Changing the parking lamp Note Take the rubber cap off the headlight lamp Turn the bulb holder about 30 counterclockwise and remove it Take t
4. Screw off the radiator cap Check antifreeze of coolant 7 25 45 C 713 49 F Ifthe antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant Check the coolant level in the radiator The radiator must be completely full Ifthe level of the cooling liquid does not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant P 152 Alternative 2 Coolant mixed ready to use 7 P 152 f you have to add more coolant than the specified value 0 501 0 53 qt Fill bleed the cooling system 4 P 111 Refit the radiator cap Position the fuel tank P 91 Mount the seat P 89 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1 w Checking the coolant level Warning A Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed cont
5. Antifreeze 40 C 40 F Supplier Motorex Motorex Anti Freeze according to SO VG 15 Specification 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 Supplier Motorex Motorex Hydraulic Fluid 75 according to JASO T903 MA P 157 SAE P 157 SAE 10W 60 Specification Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex Cross Power 4T according to SAE P 157 SAE 5 _ SUBSTANCES oa _ Specification Use only oils that comply with the specified standards see specifications on the container and that possesses the corresponding prop erties KTM recommends Motorex products Supplier Motorex Motorex Racing Fork Oil Specification KTM recommends Motorex products Supplier Motorex Motorex Chain Clean 611 Specification KTM recommends Motorex products Supplier Motorex Motorex Chain Lube 622 Strong Specification KTM recommends Motorex products Supplier Motorex Motorex Long Therm 2000 Specification KTM recommends Motorex products Supplier Motorex Motore
6. is stamped on the inner side of the fork stub The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side Clutch lever 690 SUPERMOTO The clutch lever O is fitted on the left side of the handlebar 690 SUPERMOTO R The clutch lever O is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting OPERATING ELEMENTS _2 __ 500018 01 500020 01 The hand brake lever is located on the right side of the handlebar and operates the front wheel brake The hand brake lever operates the front brake The light switch O is fitted on the left side of the handlebar Possible states z Low beam on Light switch is turned downwards In this position the low z beam and tail light are switched on High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on The headlight flasher switch is fitted on the left side of the handlebar Possible states e Headlight flasher switch in neutral position e Headlight flasher switch pressed In this position the headlight flasher high beam is actuated 500020 11 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch pressed to the right The flasher switch returns automatically to
7. P 117 TROUBLESHOOTING h A scs Faults Engine does not turn when the electric starter button is pressed Engine turns only if the clutch lever is drawn Engine turns although a gear is engaged Engine turns but does not start Possible cause Operating error Battery discharged Measure Carry out the instructions for starting P 43 Recharge the battery P 93 Check the cause of discharging Fuse 1 2 3 or 4 blown Main fuse burned out Ignition steering lock or emergency OFF switch defective Change the fuses of individual power consumers P 97 Change the main fuse P 95 Have ignition steering lock or emergency OFF switch checked Defect in safety start system The vehicle is in gear The vehicle is in gear and the side stand is folded out Have the safety start system checked Shift gear to neutral Shift gear to neutral Defect in safety start system Defect in safety start system Operating error Have the safety start system checked Have the safety start system checked Carry out the instructions for starting P 43 Fuse 4 blown Coupling of fuel hose connection not con nected Change the fuses of individual power consumers P 97 Reconnect coupling of fuel hose connec tion Socket connector of cable harness oxidized Defect in fuel injection system Clean socket connector and treat it
8. Spark plug Coolant temperature sensor on cylinder head 17N M10 M12x1 25 M12x1 5 m 12 5 Ibf ft m 8 9 Ibf ft Oil drain plug with magnet M12x1 5 m 14 8 Ibf ft Oil pressure regulator valve plug Plug oil bore Engine case stud M12x1 5 M14x1 5 15N M16x1 5 25N m 14 8 Ibf ft m 11 1 Ibf ft m 18 4 Ibf ft Loctite 243 Loctite 243 Ignition rotor nut M18x1 5 100 Nm 73 8 Ibf ft Nut engine sprocket Nut inner clutch hub Nut primary gear Plug oil screen M20x1 5 60 N M20x1 5 15N m 44 3 Ibf ft m 11 1 Ibf ft Loctite 243 M20x1 5 100 Nm 73 8 Ibf ft Loctite 243 M20LHx1 5 100 Nm 73 8 Ibf ft Loctite 2437 Plug timing chain tensioner M20x1 5 25N m 18 4 Ibf ft Screw in generator cover Plug oil thermostat M24x1 5 M24x1 5 15N 8 Nm 5 9 Ibf ft m 11 1 Ibf ft Frame Lattice frame made of chrome molybdenum steel tubing powder coated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber Suspension travel WP Suspension 4618 with Pro Lever deflector front 210 mm 8 27 in Rear Brake system 210 mm 8 27 in front Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Diameter of brake discs front Rear 320 mm 12 6 in 240 mm 9 45 in Wear limit of
9. Ifthe 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 premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary MAINTENANCE WORK ON CHASSIS AND ENGINE 1h Lean the motorcycle on the side stand Shift gear to neutral Push the chain upwards near the vertical rib of the swingarm and measure the chain tension Info e I The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions 5mm O2 Ifthe chain tension does not meet specifications Adjust the chain tension P 66 j 100130 10 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension Ifthe 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 premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can
10. Keep coolants out of the reach of children Remove the seat P 89 Reinstall the fuel tank P 90 Remove the radiator cap and the bleeder screw Tilt the vehicle slightly to the right Pour coolant in until it overflows free of bubbles and then replace the bleeder screw immediately Alternative 1 Coolant P 152 Alternative 2 Coolant mixed ready to use P 152 Fill the radiator completely with coolant Refit the radiator cap Place the vehicle on the side stand Point the fuel tank forwards Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and run it until the 5th bar of the temperature indicator lights up Switch off the engine and allow it to cool down After the engine has cooled down check the coolant level in the radiator again and add more coolant if necessary Remove the cap of the compensating tank and top up the coolant level up to the MAX marking Replace the cap of the comensating tank Position the fuel tank P 91 Mount the seat P 89 100191 10 Adjusting basic position of clutch lever e Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adj
11. Mount the rubber damper and rear sprocket carrier in the rear wheel Stand the rear wheel in the swingarm and mount the brake caliper on the brake disc Push the brake caliper support and the swingarm into the fixing location Lay the chain on the rear sprocket and fit the wheel spindle e Info Fit the chain left and right adjusters in similar positions Push the rear whell forwards so that the chain adjusters are located on the adjusting screws and tighten nut O Specification In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Taking rear from work stand P 57 e 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 Remove the rear wheel 4 P 82 Check the rubber dampers of the rear hub for damage and wear Ifthe rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub L s i y A 100148 10 Lay the read wheel on a workbench with the rear sprocket facing
12. Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocycle seal the exhaust system to prevent penetration by water First remove coarse dirt particles with a gentle water spray Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner P 155 e Info Use warm water containing normal motorcycle cleaner and a soft sponge If you have ridden the vehicle on salted roads clean it with cold water Warm water would reinforce the effect of the salt After rinsing the motorcycle thoroughly with a soft jet of water dry it with compressed air and a cloth OO CLEANING j k E W 39 Ti Z Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up and then apply the brakes e Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate Push back the protection covers on the handlebar instruments to allow water to evaporate Aft
13. together For safety reasons the chain has no chain joint Always have the chain replaced in an authorized KTM workshop where the necessary chain 100132 10 rivet tool is available Check chain guides for tightness and wear MAINTENANCE WORK ON CHASSIS AND ENGINE h Checking chain wear Shift into neutral pull the lower chain section with the specified weight O Specification Weight of chain wear measurement 15 kg 33 Ib Measure the distance of 18 chain links in the lower chain section e Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest 272 mm 10 71 in CSE 12 3 chain section If the distance O is greater than the specified measurement Have the chain changed e Info When the chain is replaced the rear sprocket and engine sprocket O OO O should also be changed 16 17 18 New chains wear out faster on old worn sprockets For safety reasons the chain has no chain joint Always have the chain 100133 10 changed in an authorized KTM workshop where the necessary tool is available MAINTENANCE WORK ON CHASSIS AND ENGINE 7 Checking brake discs 0 Warning Danger of accidents Reduced braking due to worn brake discs Worn brake discs should be replaced immediately in an authorized KTM workshop Check the thickness of the front and rear brake discs at s
14. 2 5 4 4 dte seeds a Bde oe 32 Filling up Fuel RIA a del s y dy ena ed ERI PROINT gh ace 51 Flasher switch llle 21 Flashing code lesen 129 131 Foot brake pedal ooo rrr a a a alal alal lk kl da 37 checking free play kk kk kk kk KI KI KIRI KIRI KIRI KI KI KI KI K K KIIR 76 FOLK ada su cantons edis 58 Adjusting compression damping Sk kk R KK 58 Adjusting rebound A kk kk llle 59 Bleeding fork legs lee 63 Fork part number LL LV AV VII KIRI KIRI KIRI KI KI KI KI KI K K K K 17 Front wheel ATES PP xc O E E A e 81 FEMOWING o 2 State yab mat e etd oh s DU Suc e ACA CIE amp ae 80 Fuel tank POSITIONING cue Emu mm 91 reinstalling y i jl gt cte ure Ree RR eR Bun RO Xay heim 90 Filel taps 12 do dtu a 33 Fuel oils ete 2 x A Sallana A Iu RM Ws 7 Fuse of individual power consumer changing 97 Hand brake lever KK KK eee 20 adjusting basic position 0 2 llle 71 Handlebar angle ad JUST i eund way gly Ah va ret aw dae ed 117 Handrails A 2 eia hm C HE a teed SIE IR RO UR 33 Headlight Adjusting the light range o oo ooooooooooo 105 Headlight flasher switch o o o o o oooo 21 Headlight mask with headlight HELIN LA DOT ND RIN E Bo ES 100 A bm 99 HOM 2 85 cece eue epe CE etd eg oe Roe da 22 Ignition lock llli 22 Indicator lights llle 25 Key number kK KK KK KK
15. Disconnect spring O Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play O Specification Free play at foot brake lever 3 5 mm 0 12 0 2 in Ifthe free travel does not meet specifications Have the free travel corrected in an authorized KTM workshop Reconnect spring O 100182 10 Warning b Danger of accidents Brake system failure MMINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further T Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir gt Ifthe fluid level reaches the MIN marking O Top up the brake fluid of the rear brake A P 77 Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further MAINTENANCE WORK ON CHASSIS AND ENGINE zs 0 Warning Skin irritations Brake fluid can cause skin irritat
16. Display u eee 26 NJr adiat m 45 Combination instrument speed display 27 Shifting TIOS 5 oco eiie bar booten ota olt ca ee ugs 45 Setting kilometers or miles 27 Braking uet t estatuto ada 48 Combination instrument time ceccccccccccccccccccccccecccccccccecccccce 28 Stopping parking o ee dec mu c te ads 49 CONTENTS lg A ite ce ihn P dle sean hee 51 Adjusting basic position of handbrake lever 71 GREASING AND SERVICE TABLE eere 53 Checking front brake fluid level 71 Important maintenance work to be carried out by an Topping up the front brake fluid 72 authorized KTM workshop ke 53 Bikinis nia 75 Important maintenance work to be carried out by an Checking the front brake liningS u eez 75 authorized KTM workshop as additional orden 55 Checking free play of foot brake lever e 76 MAINTENANCE WORK ON CHASSIS AND ENGINE 56 Checking rear brake fluid level 8 77 Jacking up front of motorcycle hk k s keke 56 Topping up brake fluid of front brake 23 Taking front from work stand E heHeeHe 56 Checking rear brake linings khkhkE ke 79 E up e of n p YR S SS TARTE UA Removing front wheel A eee 80 ake the rear from the work stand kk ee Fork shoc
17. KII KII 31 BON YEN rera A la 26 Display ODO ue iade ale dik Rene 29 Display TRIP S ast d n n b le Re e e Eae e dein 31 Function buttons xe n a alan rye kk Sa NES 24 Indicator lights kak nala un xw l ue Kck de Q 25 Setting kilometers or miles RR RR KI KK 27 Setting the clock llle 28 Setting resetting TRIP 1 display sn 29 Setting resetting TRIP 2 display len 30 Speed display El kl ka y kk d l 27 Tachometer az wei a la dya he bariya ENT RE RR 25 A DD E Me ah Sad 28 Conservation for winter operation 134 Coolant draining cedo a ad e t Hee 110 Coolant level CHECKING vea She ade a E 106 109 Cooling system llle 106 filling bleeding len 111 D Display n k n Es Dad Ss tv uto ps ver Rd 26 E Electric starter button o o o o o o oo ooo ooo 23 Emergency OFF switch o o o o ooo oo 23 Engine kun nin gi I sxe A ane Sea kaka a a len EAT CELERE 39 Engine number 0 0 00 cc cee ee eee 17 Engine oil CHANGING an k ee are RS Rd 118 draining ae vrs cite Eee aae LE Reg Bs 118 Hnc 123 topping UD vs VR RR eR hd b e ELLA 124 Engine oil level CHECKING 4 x aum ita Rardin tm we RAIDER 117 Environment LL 2 baya k a Pk an EN ky ee Sek aA hen kak ola 8 INDEX ss F Filler cap Gl SITig vue scr eui eder HHH BIH 32 OPONE
18. LED Licence plate lamp W2 1x9 5d 12V BW Validity Front tire Rear tire 160 60 R 17 69 H TT Bridgestone BTO9OR Pro 160 60 R 17 69 H TL Dunlop Sportmax GPR Alpha 10 Super unleaded ROZ 95 RON 95 PON 91 P 152 2516 a TECHNICAL DATA FORK gt as Fork part number 690 SUPERMOTO Fork part number 690 SUPERMOTO R 14 18 7D 08 Compression damping 690 SUPERMOTO R Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Spring length with preload spacer s 430 mm 16 93 in Spring rate Weight of rider 65 75 kg 143 165 Ib 4 8 N mm 27 4 Ib in Weight of rider 75 85 kg 165 187 Ib 5 2 N mm 29 7 lb in Weight of rider 85 95 kg 187 209 Ib Air chamber length 100 32 mm 3 947138 in Fork oil P 153 SAE 5 TECHNICAL DATA SHOCK ABSORBER 1 0 _ ss Shock absorber part number 690 SUPERMOTO Shock absorber part number 690 SUPERMOTO R 15 18 9D 07 15 18 7D 08 Shock absorber Compression damping high speed 690 SUPERMOTO R WP Suspension 4618 with Pro Lever deflector Spring preload Comfort 2 turns Standard 1 5 turns Sport 1 turn full payload 1 turn Compression damping low speed 690 SUPERMOTO R Comfort 20 clicks Standard 15 clicks Sport 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sp
19. MODE button to adjust the hour Press the SET button to adjust the minute Keep the MODE button and the SET button pressed simultaneously v The time is set In ODO mode the total distance covered is shown in kilometers or miles e Info This value remains intact even if the battery is disconnected and or the fuse blows 2308 88 38H 700120 01 e Info The tripmaster TRIP 1 operates constantly and counts up to 999 9 You can use the tripmaster to measure trips or the distance between refuelling stops After reaching 999 9 the tripmaster begins again at 0 0 Turn the ignition key to the position O Press the MODE button several times until the TRIP 1 display mode is active Keep the SET button pressed Y The TRIP 1 display is at 0 0 e Info The tripmaster TRIP 2 operates constantly and counts up to 999 9 You can use the tripmaster to measure trips or the distance between refuelling stops After reaching 999 9 the tripmaster begins again at 0 0 Turn the ignition key to the position Press the MODE button several times until the TRIP 2 display mode is active Keep the SET button pressed Y The TRIP 2 display is at 0 0 When the fuel level reaches the reserve mark the display automatically changes to TRIP F and begins to count from 0 0 regardless of which display mode was previously active e Info Parallel to the TRIP F display the fuel warning li
20. fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary MAINTENANCE WORK ON CHASSIS AND ENGINE ag Lean the motorcycle on the side stand Shift gear to neutral Loosen nut Q Loosen nuts Adjust the chain tension by turning the adjusting screws left and right Specification Chain tension 5 mm 0 2 in Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned e Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Tighten nuts Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut O Specification Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters can be turned by 180 Checking rear sprocket engine sprocket for wear Check rear sprocket engine sprocket for wear Ifthe rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket e Info The engine sprocket rear sprocket and chain should always be replaced
21. 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 The charge state and the type of charge are very important for the service life of the battery Fast recharging with a high charge current shortens the battery s service life If the charge current the charge voltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery is discharged from starting it must be recharged immediately If it stands for a long time in a discharged state the battery becomes over discharged and sulfated and then it is destroyed The battery is maintenance free i e the acid level does not have to be checked Switch off all power consuming components and switch off the engine Reinstall the fuel tank P 90 Disconnect the minus negative cable of the battery to avoid damage to the motorcy cle s electronics MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1 xx 100151 10 Changing the main fuse Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the bat tery and to test the generator With this device you cannot overcharge the battery e Info Never remove the lid O Charge the battery acc
22. or the sewage system e Info This motorcycle is equipped with a regulated catalyst Leaded fuel will destroy the catalyst You should therefore use unleaded fuel only Switch off engine Open the filler cap 7 P 32 Fill the fuel tank with fuel up to measurement Q Specification Measurement of Q 50 mm 1 97 in Fuel tank content 13 51 Super unleaded ROZ 95 RON 95 3 57 US gal PON 91 P 152 Close the filler cap P 32 Press the SET O function button for 2 seconds The fuel level warning lamp O switches off TRIP F is set to O and appears in the previous display mode e Info If you do not press the SET function button the reset takes place automati cally after about 3 minutes Important maintenance work to be carried out by an authorized KTM workshop Engine Change engine oil and oil filter clean oil screens 4 P 118 Check and adjust valve clearance Check engine mounting screws for tightness Replace spark plug Check engine bolts accessible from outside for tightness Fuel injection Check connection boots for cracks and leakage A Read out the error memory with a KTM diagnostic tool A Check fuel hoses SLS hoses and vent hoses for damage correct fit ting and leaks amp Clean check and grease the O ring of the fuel hose connection A Check the cable harness of the throttle valve body for damage and cor rect positioning 4 Check
23. protective case on the underside of the seat 500031 10 The tool set is located in the storage compartment under the seat o E Y Mh 500032 10 K 9 To The passenger footrests O can be folded in and out Possible states e Passenger footrests folded up For operation without a passenger e Passenger footrests folded down For operation with a passenger 500036 10 OPERATING ELEMENTS gt 3x Shift lever The shift lever Q is mounted on the left side of the engine 100110 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 100111 10 The footbrake pedal is located in front of the right footrest The footbrake pedal operates the rear brake The side stand O is coupled with the safety electric starter system see the riding instruc tions Possible states e Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active e Side stand folded in This position is mandatory for all journeys The safety electric starter system is inactive 500034 10 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION xs Advice on first use de A Danger Danger of accidents Danger from inadequate traffic experience Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs Warning Risk
24. radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately MAINTENANCE WORK ON CHASSIS AND ENGINE gy A Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Remove the seat P 89 Reinstall the fuel tank P 90 Condition Engine is cold Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank O Check antifreeze of coolant 25 45 C 13 49 F Ifthe antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant 100164 10 Check the coolant level in the compensating tank The coolant level must be between MIN and MAX If the level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant P 152 Alternative 2 Coolant mixed ready to use 7 P 152 Replace the cap of the compensating tank 100165 10
25. reached Pay careful attention to the prescribed running in period inspection and maintenance intervals If you observe these exactly you will en sure a much longer service life for your motorcycle The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer s service record since otherwise no warranty claims will be recognized No warranty claims can be considered for damage resulting from manipulations and alterations to the vehicle You should use the fuels oils and greases according to specifications as listed in the owner s manual 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 For the latest KTM PowerParts for your vehicle see International KTM Website http www ktm com Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances Switch off the engine and remove the ignition key Use straps or other suitable devices to secure the motorcycle against accidents or falling over Offroad motorcycling is a w
26. run out Check the tire condition P 86 Checking the tire air pressure P 87 FER mw LY TR wec recktechanwean Pe A o CI CI Check rear sprocket engine s for tightness Check rear sprocket engine sprocket for wear P 68 Check the chain tension a P 65 Clean the chain e O a or fr fo Check wheel bearing for play BT e e or Checking the rear hub rubber dampers Y P 85 Jo e K10N after 1 000 km 621 4 mi K50A every 5 000 km 3 107 mi K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years Important maintenance work to be carried out by an authorized KTM workshop as additional order Carry out a complete fork service A Poe Carry out a complete shock absorber service V i eit Clean and grease steering head bearing and sealing elements 4 Treat electric contacts with contact spray Clean the battery terminals and treat them with contact grease Change coolant e K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years MAINTENANCE WORK ON CHASSIS AND ENGINE ce Jacking up front of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Jack up the rear of the motorcycle P 57 Move the handlebar to the straight ahead position Align the work stand to the front
27. system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately MAINTENANCE WORK ON CHASSIS AND ENGINE m A Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Remove the seat P 89 Reinstall the fuel tank P 90 Stand the vehicle upright Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Fit screw with a new seal and tighten it Specification Plug drain hole of water pump M10x1 15 Nm 11 1 Ibf ft 100192 10 Filling bleeding the cooling system 4 Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants
28. the antifreeze and colant level P10 TJ Check the functioning of the radiator fan 4 Check the exhaust system for leaks and correct fitting and check that the exhaust clamps are tight 4 Check Bowden cables for damage smooth operation routing without sharp bends and setting Check correct the fluid level of the hydraulic clutch P 114 Check air filter and change if necessary Clean the air filter box 4 Check cables for damage and routing without sharp bends A Check the headlamp setting P 104 Attachments DT TT TT TT TT xe Tea Tewa Tac Tan check he functioning ot e EE 1 1 LE Brakes Chassis Wheels Check screws and nuts for tightness Check the front brake linings P 75 Check the rear brake linings P 79 Cnedetebexedses Pep zar 00000 qos qoe eee Check he ron bake b ke nud Nee ope pm 0 se IE Check the rear brake fluid level P 77 Change brake fluid A Check brake lines for damage and leakage Check the free play of the foot brake lever P 76 Check braking Check screws and guide bolts of brake system for tightness e Check shock absorber and fork for leakage and functioning Bleed fork legs P 63 Check play of steering head bearing 4 Check all screws to see if they are tight Grease Prever efectos 4 Check the spoke tension 690 SUPERMOTO P 88 Check rim
29. to the desired position and slightly tichten the screws Move the handlebar carefully in both directions as far as it will go Ifthe handlebar instruments touch the fuel tank Correct the handlebar angle e Info The distance between the handlebar support and the handlebar clamp must be the same at the front and rear Fully tighten screw O Specification Screw handlebar clamp M8 20 Nm 14 8 Ibf ft e Info The engine oil level must be checked when the engine is at operating temperature Stand the motorcycle upright on a horizontal surface MAINTENANCE WORK ON CHASSIS AND ENGINE m Condition The engine is at operating temperature Check the engine oil level e 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 Ifthe engine oil level is not at the specified level Top up the engine oil P 124 Drain the engine oil A P 118 Remove the oil filter 4 P 120 Clean oil screens A P 121 Mount the oil filter amp P 121 Fill up with engine oil A P 123 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven 700113 01 Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause e
30. upwards and insert the wheel spindle in the hub To check the play O hold the rear wheel tight and try to rotate the rear sprocket e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm lt 0 2 in Ifthe play is more than the specified value Change all rubber dampers in the rear hub Fit the rear wheel A P 83 MAINTENANCE WORK ON CHASSIS AND ENGINE cg Tire condition checking A A A A Warning Danger of accidents Uncontrollable handling behavior caused by a flat tire For your own safety have damaged tires changed immediately Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling behavior caused by non approved tires wheels Use only tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surface must be roughened in the first 200 kilometers 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Info The type condition and air pressure of the ti
31. uu sw k a ee daa WW Ee ef ya 89 SeatloCK 5x 54i x lt aw Ca sna pea ew Re A ee Mee Q ZEK pubs 34 SHIMCIEVER duo Ay k ia 36 Shifting 2202005 l4ildevu phu 45 Shock absorber 2 00 KK KK KK KRI KK KIR eee 58 adjusting rebound damping sls 62 compression damping general KII 60 compression damping high speed adjusting 61 compression damping low speed adjusting 60 Shock absorber part number 18 Side Stand S xa 3 Aa dan alan k RR ERU data 37 INDEX J X J her Spare parts accessories 0 0 0 eee eee 8 Spoke tension CHECKING witch eee aa Eee ee 88 Staning a Sete ed VR en eee ae b k der 1 43 Steering lO oro xalik ha Qara ee he ava la pud 22 Stopping esee pb ARRAS mes re Y MEI Ede 49 SIOLage ones c AS Eu e Gyan eb uh oa aa ae Rates 135 T Tachometer sis sn kk k kl kl kr a a ASA Wa E Waa sk ke aku 25 Technical data CASSIS di S used Bee R N d c lirk W Ada hee 142 144 Chassis tightening torques o o oo ooo 148 151 ENSING ux E EA hae aha a aed a ke Mete 137 138 Engine tightening torques less 139 141 FORK crete ing de sc Oa ee aa eee TANE E ed 145 Shock absorber es 146 147 Tire air pressure CHECKING 4 a eat ted tink kw ete At A ea e dtes 87 Tire condition checking ia st Bi wR Sena ne v 86 To
32. with the adapters to the fork legs Work stand front 61029055300 e info Always jack up the rear of the motorcycle first Jack up the front of the motorcycle 500096 01 Taking front from work stand Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the work stand at the front Jacking up rear of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Insert the work stand adapter in the work stand and screw it into the link forks Work stand adapter 61029055110 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the rear and jack up the motorcy cle 500095 01 Take the rear from the work stand Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the work stand from the rear and lean the vehicle on the side stand Ea The fork and the shock absorber offer many options of adapting the chassis to your riding J style and the payload e Info To help you adapt the vehicle we have summarized our findings in Table You can find the table on t
33. with this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page amp xS The typographical and other formats used are explained in the following Eigenname Indicates a proprietary name Name Identifies a protected name Marke Identifies a brand in merchandise traffic IMPORTANT NOTES a Use definition I 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 e Info The motorcycle is authorized for public road traffic in the homologous version only A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner s manual are properly carried out Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is
34. your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Specification Maximum permissible overall weight 350 kg 772 Ib Maximum permissible front axle load 150 kg 331 Ib Maximum permissible rear axle load 200 kg 441 Ib RIDING INSTRUCTIONS 1 g Checks before putting into operation e 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 Check the engine oil level P 117 Check the engine for loss of oil Check the fuel level Bleed fork legs P 63 Specification all 1 000 km 621 4 mi Check the chain tension P 65 Clean the chain P 64 Check the tire condition P 86 Checking the tire air pressure P 87 Check the front brake brake fluid level P 71 Check the rear brake fluid level P 77 Check the front brake linings P 75 Check the rear brake linings P 79 Check brake system function Check the coolant level P 109 Check that all operating elements are correctly adjusted and free to mov
35. 0103 01 MAINTENANCE WORK ON CHASSIS AND ENGINE gt wm Remove screws O Remove oil filter cover O with O ring Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts Insert oil filter 8 and Oil the O rings of the oil filter cover Refit the oil filter cover 9 and O Mount and tighten screws Specification Screw oil filter cover M5 6 Nm 4 4 Ibf ft Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine Remove the plug with the oil screen and O rings Remove the plug with the oil screen and O rings Drain the remaining engine oil Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts 700110 01 Position oil screen with O rings Refit plug with O ring and tighten it Specification Pl
36. 2 Ibf ft 45 Nm 33 2 Ibf ft Loctite 243 Screw bottom shock absorber Screw handlebar support 45 Nm 33 2 Ibf ft Loctite 2437 M10 20 Nm 14 8 Ibf ft Screw side stand M10 35 Nm 25 8 Ibf ft Loctite 243 Lambda probe Nut frame to linkage lever Nut linkage lever to rocker arm M12x1 25 24 5 Nm 18 07 Ibf ft M14x1 5 100 Nm 73 8 Ibf ft e TT M14x1 5 100 Nm 73 8 Ibf ft Nut linkage lever to swingarm M14x1 5 100 Nm 73 8 Ibf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 Ibf ft Screw steering head Swingarm bearing adjusting ring Screw front wheel spindle M20x1 5 12 Nm 8 9 Ibf ft M24x1 5 5 25 Nm 25 Nm 18 4 Ibf ft 4 Ibf ft Nut rear wheel spindle was 5 ane J Nm 29 5 Ibf ft M25x1 5 90 Nm 66 4 Ibf ft according to DIN EN 228 ROZ 95 RON 95 PON 91 according to DOT Specification Use only brake fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Motorex Brake Fluid DOT 5 1 Specification Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze 725 45 C 713 49 F 50 Anti corrosion antifreeze 50 distilled water
37. Holding the rear wheel withdraw the wheel spindle Push the rear wheel forwards as far as possible and take the chain off the rear sprocket Pull the rear wheel and brake caliper support O together to the rear until you can swing the brake caliper support to the side Warning Danger of accidents Reduced braking due to damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Take the rear wheel out of the swing arm 100145 10 e Info Do not operate the foot brake when the rear wheel is removed Fitting rear wheel T Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the footbrake until the pressure point is reached Checking the rear hub rubber dampers A P 85 MAINTENANCE WORK ON CHASSIS AND ENGINE a Check parts for damage and wear Replace damaged or worn parts Remove the bushing Clean and grease the roll surfaces of the bushing and the shaft seal ring Long life grease P 155 Clean and grease the thread of the wheel spindle and nut O Long life grease P 155 Clean the fixing locations on the brake caliper support and swingarm
38. OWNER S MANUAL 2008 690 SUPERMOTO 690 SUPERMOTO R ART NO 3211244en Lco DEAR KTM CUSTOMER 1 gt _ gt gt gt a 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 great pleasure riding the vehicle Enter the serial numbers of your vehicle below Chassis number type label P 16 Dealer s stamp Engine number P 17 Key number P 16 The owner s manual corresponded to the latest state of this series at the time of printing However it is never possible to exclude small deviations arising from further development in design and construction All specifications are not binding KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop prudction of a particular model without prior notice KTM accepts no liability for delivery options devi ations from illustrations and descriptions as well as printing and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of delivery DEAR KTM CUSTOMER gt gt gt 1 1 1 2 2007 by KTM Sportmotorcycle AG Mattigh
39. T 5N 4 Ibf ft Copper paste Screw rear brake disc 90 SUPER MOTO R 00 30 Nm 22 1 Ibf ft Loctite 243 Screw front brake disc 690 SUPER M8 m 22 1 Ibf ft Loctite 2437 MOTO R Screw spring holder on side stand M8 m 18 4 Ibf ft Loctite 2437 bracket Screw rear footrest clamp M8 25 Nm 18 4 Ibf ft Screw rear footrest bracket M8 m 18 4 Ibf ft Loctite 243 Screw top triple clamp M8 m 8 9 Ibf ft Screw bottom triple clamp M8 m 11 1 Ibf ft Screw fork stub 15 Nm 11 1 Ibf ft C Screw steering stem M8 20 Nm 14 8 Ibf ft Screw handrail M8 6 Nm 4 4 Ibf ft Screw fuel tank bracket M8 15 Nm 11 1 Ibf ft Screw manifold on main silencer M8 25 Nm 18 4 Ibf ft Copper paste Screw upper subframe 35 Nm 25 8 Ibf ft Loctite 2437 Screw side stand bracket 25 Nm 18 4 Ibf ft Loctite 243 Screw linkage bracket front engine M8 m 18 4 Ibf ft Loctite 243 bracket Screw ignition lock M8 Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 Ibf ft Loctite 243 Screw lower subframe Engine carrying screw Remaining nuts chassis Remaining screws chassis M10x1 25 M10 M10 M10 45 Nm 33 2 Ibf ft m 33 2 Ibf ft Loctite 243 Loctite 243 Screw top shock absorber M10 N 45N 45N 5N m 33
40. absorber 690 SUPERMOTO R Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself e Info The high speed setting can be seen during the fast compression of the shock absorber MAINTENANCE WORK ON CHASSIS AND ENGINE o Turn the adjusting screw O clockwise with an open ended spanner until it stops e info Do not loosen nut Turn back counterclockwise the number of turns corresponding to the shock absorber type Specification Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn full payload 1 turn e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Adjusting rebound damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself Bleeding fork legs 100124 10 Turn the adjusting screw clockwise until it stops Turn back counterclockwise the number of clicks corresponding to the shock absorber type Specification Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks e Info Turn clockwise to
41. act a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Remove the seat P 89 Reinstall the fuel tank P 90 Condition Engine is cold Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank The coolant level must be between MIN and MAX If the level of the cooling liquid does not meet specifications Correct the coolant level 100164 10 Alternative 1 Coolant P 152 Alternative 2 Coolant mixed ready to use P 152 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 mo a D 100165 10 Draining coolant 4 Screw off the radiator cap and check the coolant level in the radiator The radiator must be completely full Ifthe level of the cooling liquid does not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant P 152 Alternative 2 Coolant mixed ready to use P 152 f you have to add more coolant than the specified value 0 501 0 53 qt Fill bleed the cooling system P 111 Refit the radiator cap Position the fuel tank P 91 Mount the seat P 89 Warning A Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling
42. al area in front of it make a mark as high as the center of the low beam headlight Make another mark at a distance of under the first mark Specification Sone Stand the motorcycle at a distance of in front of the wall and switch on the low beam Specification 56m Use a screwdriver see illustration to adjust the headlight range Specification The boundary between light and dark must be exactly on the lower mark for a motor cycle with driver e Info Turn clockwise to increase the light range turn counterclockwise to reduce the light range If you have a payload you may have to correct the headlight range 3 x The water pump O 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 Heat expansion causes excess coolant to flow into the compensating tank If the temperature falls the excess coolant is sucked back into the cooling system The specified coolant temperature is therefore permissible without danger of function prob lems 125 C 257 F The coolant is cooled by the air stream and a radiator fan which is controlled by a ther moswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Lanza Do not open the
43. arning lamp lights up Voltage in electrical system too low When you switch on the ignition all display segments light up for a second as a function test 700118 01 LEnGTth Following the display function test the wheel circumference LEnGth is shown for one sec ond e Info 1870 mm corresponds to the circumference of the 17 front wheel with a series pro Fa tn LEnBEh duction tire The display then changes to the last selected mode 700119 01 The speed O is displayed in kilometers per hour km h or miles per hour Mph 700114 01 Info If you change the unit the ODO value is retained and converted accordingly Making the setting according to the country Condition The motorcycle is standing Turn the ignition key to the position O Press the MODE button several times until the ODO display mode is active Keep the MODE button pressed until the display mode changes from Km h to Mph or from Mph to Km h Specification Activation duration of MODE button 10s 700120 01 The time is shown in area of the display e Info The time must be adjusted after the battery is disconnected or the fuse is changed Condition The motorcycle is standing Turn the ignition key to the position O Press the MODE button several times until the ODO display mode is active Keep the MODE button and the SET button pressed simultaneously Y The time begins to flash Press the
44. arting the engine management injects no fuel and the engine cannot start Press the starter for a maximum of 5 seconds Wait for at least 5 seconds until trying again This motorcycle is equipped with a safety electric starter system The engine can be started only if the gearbox is in neutral or the clutch lever is pulled If you shift into gear when the side stand is folded out and then release the clutch lever the engine stalls Take the weight off the side stand and swing it back up with your foot as far as it will go 100109 10 RIDING INSTRUCTIONS 1 1 1 w Starting up Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully Shifting riding A A A A A A Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions Warning Danger of accidents If you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can block Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehic
45. b carefully into the holder turn it about 30 counterclockwise and remove it from the holder e Info Do not touch the reflector with your fingers and try to avoid contact will oil or grease 100160 10 Check parts for damage and wear Replace damaged or worn parts MAINTENANCE WORK ON CHASSIS AND ENGINE gs Checking headlamp setting 100159 10 Press the new flasher bulb carefully into the holder and turn it clockwise as far as it will go Flasher light BAU15s P 144 Position the diffuser Insert the screw and turn it first counterclockwise until you feel it click into the thread Tighten the screw Check the flasher function 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 Make another mark at a distance of under the first mark Specification Some Stand the motorcycle at a distance of in front of the wall and switch on the low beam Specification Distance 5 m 16 ft Check the headlamp setting The boundary between light and dark must be exactly on the lower mark for a motor cycle with driver Ifthe boundary between light and dark does not meet specifications Adjust the headlight range P 105 MAINTENANCE WORK ON CHASSIS AND ENGINE ts Adjusting the headlight range 100159 10 100158 10 On a light colored wall with a horizont
46. brake discs 690 SUPERMOTO front Rear Wear limit of brake discs 690 SUPERMOTO R 4 0 mm 0 157 in 4 5 mm 0 177 in front 3 6 mm 0 142 in Rear 4 5 mm 0 177 in Tire air pressure road solo front Rear 2 0 bar 29 psi 2 0 bar 29 psi Tire air pressure with passenger fully loaded front 2 0 bar 29 psi TECHNICAL DATA CHASSIS 1 1 1 1 nm Rear wheel gearing 16 40 Chain 5 8 x 1 4 X ring Steering head angle 63 5 Seat height unloaded 880 mm 34 65 in Ground clearance unloaded 245 mm 9 65 in Weight without fuel 154 kg 340 Ib Maximum permissible front axle load 150 kg 331 Ib Maximum permissible rear axle load 200 kg 441 Ib Maximum permissible overall weight 350 kg 772 Ib Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30A Fuse 75011088015 15A Fuse 75011088010 10A Lighting equipment Headlight H4 P43t 12V 60 55 W Parking light W2 1x9 5d 12V 5W Instrument lights and indicator lamps LED TECHNICAL DATA CHASSIS 1 1 ass 690 SUPERMOTO 690 SUPERMOTO R For further information see http www ktm com Capacity fuel Fuel tank content 13 51 3 57 US gal 120 70 R 17 58H TT Bridgestone BTO90F 120 70 R 17 58 HTL Dunlop Sportmax GPR Alpha 10 Flasher light BAU15s 12V 10W Brake tail light
47. e Check the functioning of the electrical equipment Check that baggage is correctly secured Siton the motorcycle and check the rear mirror setting RIDING INSTRUCTIONS 1 1 1 0a Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Caution A Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Turn the emergency OFF switch to the position O Turn the ignition key to the position O Y 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 Shift gear to neutral V The green idling speed indicator lamp N O lights up Press the electric starter button e Info I Do not press the electric starter button until the combination instrument func tion test is finished Do not open the throttle when starting If you open the throttle when st
48. e nennen 17 Handralls suka ka a LO eek Fd evel a kak e Re EEG 33 Shock absorber part nuUMbeT occcoocccnnnnccccnnnnnnconononancconononon 18 Seat IOCK PE 34 OPERATING EEEMENTS 5n Ha Dinan aM Ie teet 19 OWNER S MANUAL o sitet tede e EET Notae oben 34 ClutclileVet ait YD DD ete eate d tet ttes 19 TOOL S6t rde sl ka nd eoe rates theod ene ande W sae K y 35 Hand brake lever 20 Passenger fOOtrests urne dit edi tete inen 35 LighE SWIECD aiti estat A Pe ERE dez 20 Nuda 36 Headlight flasher switch 21 Foot brake p dalier ae raa e a aa e NO RANA 37 BEE E 5o sees dm ee EE E EA le o A tt 21 SIde Stan dk A cites refe yaya e de dst md ei eure de po ute dos 37 FOUN i itte dec d ee ee Rede de e at eode e aru tat eed des 22 GENERAL TIPS AND HINTS ON PUTTING INTO lgnition steering lock ekey kek 22 OPERATION 27 terrre raus a a E eya CAKE aA W 38 Emergency OFF SWitCh esee 23 Advic on fIlSE USES oec e de ran kak rex eno o rre itas 38 Electric starter button csse 23 Running in the Nine cscs 39 Combination instrument LELE 24 Loading the vehicle hKA 4 lkE kk kk nn 40 Combination instrument function buttons 24 RIDING INSTRUCTIONS 2 0 cece enn 42 Combination instrument tachometerf LL 25 Checks before putting into operation U 42 Combination instrument control lamps 25 Sid eco Gama Qe aveo oss a Co noe Da 43 Combination instrument
49. educed braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Note Danger of accidents Reduced braking due to damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly re duced and the brake discs are destroyed MAINTENANCE WORK ON CHASSIS AND ENGINE 1 s Check the brake linings for minimum thickness Minimum thickness gt 1 mm gt 0 04 in If the minimum thickness is less than specified Worn brake linings should be replaced immediately in an authorized KTM work shop 100139 10 Jack up the rear of the motorcycle P 57 Jack up the front of the motorcycle P 56 Remove screw O and spacing sleeve O Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side e Info Do not pull the handbrake lever when the brake caliper is removed MAINTENANCE WORK ON CHASSIS AND ENGINE 100142 10 Loosed screw and screw O Screw out screw about 6 turns press your hand on the screw to push the wheel spin dle out of the fork stub Remove screw 6 Warning Danger of accidents Reduced braking due to damaged brake discs Always lay the wheel down in such a way that the brake disc is
50. er of accidents Reduced braking caused by spongy pressure point of front or rear brake Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Danger of accidents Brake system failure Ifthe foot brake pedal is not released the brake linings drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake RIDING INSTRUCTIONS 1 1 1 s zs 0 Warning Danger of accidents Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage 0 Warning Danger of accidents Delayed brake action on salted roads Salt can be deposited on the brake discs To achieve the normal braking effect the brake discs must first be cleaned by brak ing To brake release the throttle and operate the front and rear brakes simultaneously On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way you have to brake far less and the brakes do not overheat Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle
51. er the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain P 64 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and polishing materials for metal rubber and plastic P 156 Treat all painted parts with a mild paint polish High luster polish for paint P 156 To prevent electrical problems treat electric contacts and switches with contact spray Contact spray P 156 Oil the ignition steering lock Universal oil spray P 156 CONSERVATION FOR WINTER OPERATION ggg Conservation for winter operation e 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 you have ridden the vehicle on salted roads clean it with cold water Warm water would reinforce the effect of the salt Clean the motorcycle P 132 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance e Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Clean the chain P 64 STORAGE OB Storage Info If you want to garage the motorcycle for a lo
52. es e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated 500022 11 er 700117 01 The combination instrument is attached in fromt of the handlebar The combination instrument is divided into 4 function areas Function buttons Tachometer Indicator lights O Display Press the MODE button to change the display mode Possible display modes are total distance covered ODO tripmaster 1 TRIP 1 and tripmas ter 2 TRIP 2 Press the SET button to reset tripmaster 1 TRIP 1 and tripmaster 2 TRIP 2 to 0 0 Button has no function Erz 10086098 The tachometer O displays the engine speed in revolutions per minute The red marking shows the excess engine speed range The indicator lamps provide additional information on the operating state of the motorcycle Possible states Flashing indicator flashes green in flash rhythm Flasher light is switched on Idling speed indicator lamp lights up green Transmission is in neutral High beam indicator lamp lights up blue High beam is switched on Temperature warning lamp lights up red Coolant has reached a critical value Fuel level warning lamp lights up orange Fuel level has reached the reserve mark Display switches to TRIP F FI warning lamp MIL lights flashes orange The OBD has detected an emission or safety critical error Battery w
53. everal places on the disc to see if it conforms to measurement e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Wear limit of brake discs 690 SUPERMOTO front 4 0 mm 0 157 in 100135 10 Rear 4 5 mm 0 177 in Wear limit of brake discs 690 SUPERMOTO R front 3 6 mm 0 142 in Rear 4 5 mm 0 177 in Ifthe brake disc thickness is less than the specified value Change the brake disc MAINTENANCE WORK ON CHASSIS AND ENGINE 1 zx Adjusting basic position of handbrake lever Adjust the basic setting of the handbrake lever to your hand size by turning adjusting wheel e Info Pull the brake lever forwards and turn the adjusting wheel Do not make any adjustments while riding Checking front brake fluid level 0 Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further 0 Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop 690 SUPERMOTO The brake fluid level must not fall below the center of the level viewer 9 when the brake fluid reservoir is vertical Ifthe brake fluid level is lower tha
54. f rear brake Screw battery holder 9Q 10 Nm 7 4 Ibf ft 5 Nm 3 7 Ibf ft 3 Nm 2 2 bf ft Screw rear brake disc 90 SUPER MOTO 9Q 14 Nm 10 3 Ibf ft Loctite 243 Screw front brake disc 690 SUPER M6 14 Nm 10 3 Ibf ft Loctite 2437 MOTO Screw footbrake cylinder M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw horn M6 6 Nm 4 4 Ibf ft Loctite 243 Screw license plate holder M6 8 Nm 5 9 Ibf ft Screw ball joint of push rod on foot M6 10 Nm 7 4 Ibf ft Loctite 243 brake cylinder Screw lower radiator bracket M6 5 Nm 3 7 Ibf ft Screw fuel tap Screw magnetic holder on side stand Screw voltage regulator rectifier z o 9Q Tightening sequence tighten in p 6 Nm 4 4 arallel bf ft 10 Nm 7 4 Ibf ft Loctite 2437 8 Nm 5 9 bf ft Screw SLS valve M6 6 Nm 4 4 Ibf ft Screw headlight mask M6 5 Nm 3 7 Ibf ft Screw side stand bracket M6 10 Nm 7 4 Ibf ft Loctite 243 Screw control unit holder M6 3 Nm 2 2 Ibf ft Nut rear sprocket screw M8 35 Nm 25 8 Ibf ft Loctite 243 Nut manifold on cylinder head M8 25 Nm 18 4 Ibf ft Copper paste Remaining nuts chassis M8 30 Nm 22 1 Ibf ft Remaining screws chassis Screw exhaust clamp on main silencer Screw exhaust clamp on manifold Qo 00 00 25 Nm 18 TES ESA 25 N 18 4150 T
55. function in voltage supply circuit of EFI control unit Malfunction in side stand switch circuit Check the EFI control unit voltage supply Check the side stand switch 4 26 Fl warning lam long 6x short p MIL flashes 2x Malfunction in Hall sensor throttle valve control circuit Check the Hall sensor throt tle valve control 4 FLASHING CODE D ss Fault 27 Description Fl warning lamp MIL flashes 2x long 7x short Possible cause Malfunction in voltage supply circuit of throttle valve control unit Check the throttle valve con trol unit voltage supply A 33 37 Fl warning lamp MIL flashes 3x long 3x short Fl warning lamp MIL flashes 3x long 7x short Malfunction in injection valve circuit Malfunction in ignition coil cir cuit Check the injection valve A Check the ignition coil A 41 45 54 Fl warning lamp MIL flashes 4x long 1x short Fl warning lamp MIL flashes 4x long 5x short Fl warning lamp MIL flashes 5x long 4x short Fault short circuit in fuel pump control circuit Malfunction or short circuit af ter positive in lambda probe heating circuit Fault short circuit in secondary air valve circuit Check the fuel pump con trol Check the lambda probe heating 4 Check the secondary air valve A 55 58 Fl warning lamp MIL flashes 5x long 5x short Fl warnin
56. g lamp MIL flashes 5x long 8x short Malfunction in throttle valve control unit circuit internal Malfunction in release of throt tle stepper in EPT mode Check the throttle valve con trol unit 4 Check the throttle valve con trol unit 4 Check the EFI control unit A 60 68 90 Fl warning lamp MIL flashes 6x long Fl warning lamp MIL flashes 6x long 8x short Fl warning lamp MIL flashes 9x long Malfunction in throttle stepper circuit Connection of pressure sensor of induction manifold leaky Throttle valve position not plau sible Check the throttle stepper motor A Check the connection of the pressure sensor of the induction manifold 4 Check the throttle valve po sition A Fault 91 92 FI warning lamp MIL flashes 9x Malfunction in CAN bus com Check CAN bus communica long 1x short munication tion 4 FI warning lamp MIL flashes 9x Malfunction in voltage supply Check the throttle valve con long 2x short circuit of throttle valve control trol unit A unit internal CLEANING tz i TT Cleaning motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment Never clean the vehicle with high pressure cleaning equipment or a strong water jet The excessive pressure can penetrate electrical components connects Bowden cables and bearings etc and can damage or destroy these parts
57. ght they can break due to local overload Check the spoke tension regularly especially on a new motorcycle To check spoke tension tap each spoke with a screwdriver Specification You should hear a high note Spoke nipple front wheel M4 5 5 Nm 3 7 Ibf ft Spoke nipple rear wheel M5 5 Nm 3 7 Ibf ft e Info If you hear different tone frequencies from different spokes this is an indication of different spoke tensions Insert the ignition key in the seat lock and turn it 45 counterclockwise Lift up the seat at the rear pull it back and remove from above Suspend the seat on the screw press the rear downwards and at the same time push it forwards The two projections must be inserted into the frame Push the locking pin into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click Remove the ignition key from the seat lock Finally check that the seat is correctly mounted MAINTENANCE WORK ON CHASSIS AND ENGINE gy Reinstalling the fuel tank 0 Remove the seat P 89 Remove screw OQ e Info The fuel lines do not need to be disconnected Laya cloth over the subframe and straighten the steering Carefully raise the fuel tank and move it backwards Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat ing tank see ill
58. ght begins to light up The temperature indicator in the display consists of 12 bars The more bars that light up the hotter the coolant When the top bar lights up all bars begin to flash simultaneously and the temperature warning lamp begins to light up Possible states Engine cold up to four bars e Engine at normal operating termperature from five to eleven bars e Engine hot all twelve bars flash Lift the cover of the filler cap O and insert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap e Info The filler cap has a tank air vent system Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover 500030 10 The fuel taps are located on the left right under the fuel tank Possible states Fuel supply closed 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 e Fuel tap open The knurled screws are turned counterclockwise as far as possible The level can be compensated and the fuel can flow out of the fuel tank The handrails 9 are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey The seat lock is located to the right of the seat You can lock it with the ignition key You can find the owner s manual in its
59. he air filter box under the seat These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds e Info The hydraulic compression damping determines the fork suspension behavior Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs MAINTENANCE WORK ON CHASSIS AND ENGINE gt Turn back counterclockwise the number of clicks corresponding to the fork type Specification Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Adjusting rebound damping of fork e Info The hydraulic rebound damping determines the fork suspension behavior Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs MAINTENANCE WORK ON CHASSIS AND ENGINE gw Turn back counterclockwise the number of clicks corresponding to the fork type Specification Rebound damping Comfort 20 clicks Standard 15 clicks S
60. he headlight bulb out of the headlight housing Check parts for damage and wear Replace damaged or worn parts Insert a new headlight bulb into the headlight housing Headlight H4 P43t P 143 e Info Insert the headlight bulb so that the bayonet lugs O latch into the slots Position the bulb holder and turn it clockwise as far as it will go Replace the rubber cap Refit the headlight mask with the headlight P 100 Damage to reflector Keep the glass of the bulb free of grease After fitting the bulb in the holder clean the glass with a clean cloth Any grease on the glass will evaporate by the heat and be de posited on the reflector Switch off all power consuming components and switch off the engine Remove the headlight mask with the headlight P 99 Pull the parking light bulb out of the holder Check parts for damage and wear Replace damaged or worn parts Insert a new parking light bulb in the holder Parking light W2 1x9 5d P 143 Refit the headlight mask with the headlight P 100 lasher bulb Note Damage to reflector Keep the glass of the bulb free of grease After fitting the bulb in the holder clean the glass with a clean cloth Any grease on the glass will evaporate by the heat and be de posited on the reflector Remove the screw on the rear of the flasher housing Carefully swing the diffuser forwards and remove it Press the flasher bul
61. hen you reach maximum speed after fully opening the throttle turn back the throttle to about 3 4 of its range the speed hardly drops but the fuel consumption falls consid erably Open the throttle only as far as the road and weather conditions permit Particularly in bends do not shift and open the throttle only very cautiously To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again RIDING INSTRUCTIONS 1 1 1 1 1 1 4 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 Switch off the engine if you expect to be standing for a long time Ifthe Fl warning lamp MIL starts to light up during the journey stop immediately If you shift to neutral the Fl warning lamp MIL begins to flash e Info From the flash rhythm you can deduce a two digit number the so called flash code The flash code tells you which component is affected by a fault Braking A A A A Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Warning Dang
62. ications Remove screw with membrane Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 P 153 Check parts for damage and wear Replace damaged or worn parts Refit screw with membrane Move the handlebar to the straight ahead position Move the throttle grip backwards and forwards to ascertain the play in the gas Bowden cable Play in gas Bowden cable 3 5 mm 0 12 0 2 in Ifthe gas Bowden cable play does not meet specifications Adjust the play in the gas Bowden cable P 116 400192 10 MAINTENANCE WORK ON CHASSIS AND ENGINE tg Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change Ifthe idle speed changes Adjust the play in the gas Bowden cable 4 P 116 Adjusting play in gas Bowden cable Move the handlebar to the straight ahead position Loosen the lock nut Adjust the play in the gas Bowden cable by turning the adjusting screw Specification Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten the lock nut O 100195 10 P Loosen screw Move the handlebar
63. id and provides greater safety for high demands Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position MAINTENANCE WORK ON CHASSIS AND ENGINE 1 w 690 SUPERMOTO Remove screws Remove the cover with membrane Top up brake fluid to level Q Specification Measurement of Q 5 mm 0 2 in ad m Brake fluid DOT 5 1 P 152 r Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws e Info Clean up overflowed or spilt brake fluid immediately with water 690 SUPERMOTO R Loosen screw Remove the cover with membrane Top up the brake fluid to MAX level Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws e Info Clean up overflowed or spilt brake fluid immediately with water MAINTENANCE WORK ON CHASSIS AND ENGINE 1 15 Brake linings The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties The type names of brake pads are entered in the homologation d
64. increase damping turn counterclockwise to reduce suspension damping Lean the motorcycle on the side stand Remove bleeder screws briefly Y Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws e info Carry out this action on both fork legs MAINTENANCE WORK ON CHASSIS AND ENGINE 1h Checking chain dirt Check the chain for coarse dirt accumulation Ifthe chain is very dirty Clean the chain P 64 Cleaning the chain T Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material 0 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info The service life of the chain depends largely on its maintenance Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner P 155 After drying apply chain spray Onroad chain spray P 155 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension
65. ion on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends DOT 5 1 brake fluid from Motorex This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1 zs Stand the vehicle upright Remove screw cover with membrane Top up the brake fluid to MAX level Brake fluid DOT 5 1 P 152 Check parts for damage and wear Replace damaged or worn parts Refit screw with membrane e Info Clean up overflowed or spilt brake fluid immediately with water Checking rear brake linings Warning Danger of accidents R
66. ithout a battery In both cases electrical components can safety equipment can be damaged The vehicle is then no longer safe to ride MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1 1s Installing the battery Push the battery from the right into the battery rack e info The battery terminals must be at the front Secure the battery with the rubber band O Attach the positive cable and replace the positive terminal cover Attach the minus cable Position the fuel tank P 91 Mount the seat P 89 Set the clock P 28 4 Warning 4 Risk of injury Battery acid and battery gases cause serious cauterization 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 fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator MAINTENANCE WORK ON CHASSIS AND ENGINE 1 Warning Environmental hazard Problem materials cause environmental damage Dispose of
67. ividual power consumers 97 Checking rear sprocket engine sprocket for wear 68 Removing headlight mask with headlight 99 Checking chain wear sess 69 Refitting the headlight mask with the headlight 100 Checking brake discs 70 Changing headlight bulb cccccseccceeeeeeceeeeeeeeeeeeseeeees 101 CONTENTS tg Changing the parking lam 102 Changing flasher DUID wists oco rette don 103 Checking headlamp Setting ccccscccseecaeeeeeeeeeeeeeeeseeees 104 Adjusting the headlight range hKAL AGZAX E 105 Cooling A ror e SUR dies ede tae Ae E TR QUE ERA oes 106 Checking antifreeze and coolant level 106 Checking the coolant level 109 Draining coolant A eee 110 Filling bleeding the cooling system 111 Adjusting basic position of clutch lever j 113 Checking correcting fluid level of hydraulic clutch 114 Checking play in gas Bowden cable 115 Adjusting play in gas Bowden cable amp 116 Adjusting the handlebar angle Aoi 117 Checking engine oil level A kk 117 Changing engine oil and oil filter cleaning oil Sacs HET 118 Draining engine oil VM eee 118 Removing the oil filter VM 120 Mounting oil filter JM 121 Cleaning oil screens VM 121 Filling
68. k absorber 2 eterne edid pad ea kde eadera 58 Fitting vent wheel Wh Jesse 2 i kwa Removing rear wheel A 82 Adjusting compression damping of fork ai 690 SUPERMOTO R s5 sn en ne ese Kr l ke den a sg Fitting rear wheel V sse 83 Adjusting rebound damping of fork 59 Checking the rear hub rubber dampers A 85 Compression damping of shock absorber Tire condition checking khK hE Bil kk kk kk 86 690 SUPERMOTO R kk merenti 60 Checking tire air pressure oocoocccoccconcconnnonnnncncnnnconanonnnoninnnns 87 Adjusting the low speed compression damping of the shock Checking spoke tension 690 SUPERMOTO 88 absorber 90 SUPERMOTO R KK 60 Removing the seat MAk L kk kk ee 89 Adjusting high speed compression damping of the shock Mounting tlie seat zb e re ua 89 absorber 690 SUPERMOTO R EEE 61 Reinstalling the fuel tank kMA A L keke 90 Adjusting rebound damping of the shock absorber 62 Positioning the fuel tank ekey 91 Bleeding fork l yona Halan ER KENE e hEN e d e NR A 63 Removing the battery eee 92 Checking chain dirt A 64 Installing the battery M 93 Cleaning the chain pi 64 Recharging the battery A eee 93 Checking the chain tension ip D p EA 65 Changing the main fuse EEE kk kk kk 95 Adjusting chain t nsi N Zik xila usane kela ebeke ee 66 Changing fuses of ind
69. le 16 Light switch Loading the vehicle Main fuse changing INDEX jUj 18 Maintenance ayn eyn AN Wan ese 7 Motorcycle cleaning acti eee Ae ead red aW ER i eS 132 jacking p front piee fad bale ORE eO 56 jacking Up Tea eu siyan d deae eR RR Rom e ES Are raj 57 taking front from work stand lernen 56 taking rear from work stand llle 57 Dil filter wir agane a ae E 118 TIEFE A kk A kab aleteke fre oda ate tb dih dr t wa bet iul d 121 removing aon A 120 0il screen cleaning taa RC eR d PR sea Nes 118 0il screens cleaniflig uses ea a A n hr ded 121 OWNER S MANUAL kk kK KK KK KIRI IA 34 BASICS Leidensi A NORRIS a ok Vu 9 Parking iii rU Rd eden ees US 49 Passenger footrests o o oooooooooooo oo 35 Play in gas Bowden cable adjusting A HHHH 116 ghieeking s das RU IDEE 115 Putting into operation Advice on first use after storage sa buscad ek E geri Voie lk aa Xd 136 Checks before putting into operation 42 R Rear hub rubber dampers CHECKING sio ae oce frr id aa ERE 85 Rear sprocket engine sprocket checking for wear kk KEK KI ee KK 68 Rear wheel MELISSA E e Vr y ted 83 LEMOVING gt ayak D Anay n a ag a Sta andro VER EUR add 82 Ridilgo i roo A epe Ene A EAR ADDE 45 Starting Up casu ede ee kalana k La tue e 45 S Seat MOUNN ce ete teat id eec died ate 89 FEMOVING
70. le is at a standstill Warning Risk of injury The passenger must be capable of sitting correctly on the passenger seat The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests Note the regulations governing the minimum age of passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible RIDING INSTRUCTIONS 1 1 1 1 1 w A A Note Warning Danger of accidents Reduced road grip with cold tires 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 Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surface must be roughened in the first 200 kilometers 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to sli
71. lt 02 06 Description Fl warning lam briefly 2x Fl warning lam briefly 6x p MIL flashes p MIL flashes Input signal from throttle valve sensor too low high Check the throttle valve sen sor A 08 09 Fl warning lam briefly 8x Fl warning lam briefly 9x Fl warning lam long 2x short p MIL flashes p MIL flashes p MIL flashes 1x Input signal from throttle grip sensor too low high Input signal from pressure sen sor of induction manifold too low high Input signal from coolant tem perature sensor too low high Check the throttle grip sen sor A Check the pressure sen sor of the induction mani fold Check the temperature sen sor coolant A Fl warning lam long 3x short Fl warning lam long 4x short p MIL flashes 1x p MIL flashes 1x Input signal from intake air temperature sensor too low high Input signal from ambient air pressure sensor too low high Check the intake air temper ature sensor Check the ambient air pres sure sensor Fl warning lam long 5x short Fl warning lam long 7x short p MIL flashes 1x p MIL flashes 1x Input signal from roll angle sen sor too low high Malfunction in lambda probe circuit Check the roll angle sen sor A Check the lambda probe 4 24 25 Fl warning lam long 4x short Fl warning lam long 5x short p MIL flashes 2x p MIL flashes 2x Mal
72. moving ur do VERE ey cA A eb ae bee 92 Brake discs CHECKING 5 xau Sen Rega e ARE Baek wed 70 Brake fluid of rear brake adding K KRI KIRI ee KIIR 77 Topping up brake fluid of front brake 72 Brake fluid level Checking the front brake brake fluid level 71 of rear brake checking kK KR KIRI RI KIRI KI KIR KIRI KK 77 Brake linings 4 5544 5 E GA xuk ab ie kr es 75 Checking the front brake brake fluid level 75 of rear brake checking llle 79 pro PCT 48 Braking uud cadere rupibus SEU 48 C Chain chiecking dilt oer Ree EET 64 checking wear luas ree Rer em Rp uo KIRI T als E 69 INDEX 9 J J 0 D 188 cleaning uoi bal exu CARNE RW Ee a 64 Chain tension adJUstilig us ahh ue biy be Reuter a ERR enu 66 CHECKING i94 dua risu ev ete st teg av aA a nana LE 65 Changing flasher bulb 103 Changing headlight bulb lt 101 Changing parking lamp 102 Chassis number 00 00 cece eee eee 16 Checking headlamp setting 104 Cleaning x1 3 Pe ne bine Sae t hy duced 132 133 Clutch checking correcting fluid level 114 Clutch ever ral aia 19 adjusting basic position o o oo oo ooo ooo 113 Combination instrument ooooo momo 24 Coolant temperature indicator kk KI KI
73. n the center of the level viewer Top up the brake fluid of the front brake A P 72 690 SUPERMOTO R The brake fluid level must not fall below the MIN marking when the brake fluid reservoir is vertical If the brake fluid is below the MIN marking Top up the brake fluid of the front brake A P 72 ric E Topping up the front brake fluid Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further MAINTENANCE WORK ON CHASSIS AND ENGINE 1 xn A A Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends DOT 5 1 brake fluid from Motorex This has a higher wet boiling point than DOT 4 brake flu
74. nger 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 In this way you can avoid long workshop waiting times at the start of the new season Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle P 132 Change engine oil and oil filter clean oil screens A P 118 Check the antifreeze and coolant level P 106 Checking the tire air pressure P 87 Remove the battery amp P 92 Recharge the battery A P 93 Specification Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place should be dry and not subject to large temperature differences e Info KTM recommends jacking up the motorcycle Jack up the rear of the motorcycle P 57 Jack up the front of the motorcycle P 56 STORAGE _ 43 T Cover the motorcycle with a porous sheet or blanket Info e Do not use non porous materials since they prevent humidity from escaping 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 condenses and causes valves and exhaust system to rust Putting i
75. not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check parts for damage and wear Replace damaged or worn parts Clean and grease the thread of the wheel spindle and screw Long life grease P 155 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw O Specification Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft Position the brake caliper and check that the brake linings are seated correctly MAINTENANCE WORK ON CHASSIS AND ENGINE amp c p CR 100168 10 Position the spacing sleeves Mount and tighten screws 6 Specification Screw front brake caliper M10x1 25 45 Nm Loctite 2437 33 2 Ibf ft Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc Take the front from the work stand P 56 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Fully tighten screw O Specification Screw fork stub M8 15 Nm 11 1 Ibf ft Taking rear from work stand P 57 100144 10 Jack up the rear of the motorcycle P 57 Remove nut Remove chain adjuster O
76. nsumers 0 e Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consuming components and switch off the engine Remove the seat P 89 Open the fuse box cover Remove defective fuse Specification Fuse 1 10A ignition combination instrument alarm system optional Fuse 2 10A clock ignition EFI control unit Fuse 3 10A throttle valve control unit Fuse 4 10A fuel pump Fuse 5 10A radiator fan Fuse 6 10A horn brake light flasher light alarm system optional Fuse 7 15A high beam low beam parking light tail light license plate lamp Fuse 8 10A for supplementary equipment accessories connected with ignition switch Fuse 9 10A for supplementary equipment standard accessories Fuse 10 not used Fuse SPARE 10A 15A spare fuses Check parts for damage and wear Replace damaged or worn parts e Info A defective fuse is shown by a burned out fuse wire O MAINTENANCE WORK ON CHASSIS AND ENGINE 1 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 P 143 Fuse 75011088015 P 143 e info If the new fuse burns out contact an authorized KTM workshop
77. nto operation after storage Take the front from the work stand P 56 Taking rear from work stand P 57 Recharge the battery P 93 Install the battery P 93 Set the clock P 28 Fill up with fuel P 51 Carry out checks before putting into operation P 42 Make a test ride TECHNICAL DATA ENGINE tg Displacement 654 cm 39 91 cu in 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 Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Bronze bush Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 rotor pumps Primary transmission 36 79 Clutch APTC antihopping clutch in oil bath hydraulically actuated Gearbox 6 gears claw shifted Transmission ratio 1st gear 14 35 2nd gear 16 28 4th gear 21 23 bth gear 23 22 Capacity engine oil Engine oil 1 701 1 8 qt 6th gear Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment type Kokusan Generator 12V 224W Spark plug NGK LKAR 8AI 9 spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water
78. nvironmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations MAINTENANCE WORK ON CHASSIS AND ENGINE tt e Info Drain the engine oil only when the engine is warm Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine Remove the oil drain plug 6 with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet Check parts for damage and wear Replace damaged or worn parts Refit the oil drain plug with the magnet and seal ring and tighten it Specification Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE 1 mw Removing the oil filter Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine Remove screws Remove oil filter cover with O ring Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 70
79. ocuments Info Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Checking the front brake linings 0 Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Note Danger of accidents Reduced braking due to damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly re duced and the brake discs are destroyed Check the brake linings for minimum thickness Minimum thickness gt 1 mm gt 0 04 in If the minimum thickness is less than specified Worn brake linigs should be replaced immediately in an authorized KTM work shop Warning Danger of accidents Brake system failure If there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications
80. of injury Risk of injury by missing inadequate protective clothing Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the motorcycle Always wear protective clothing which must be in perfect condition and meet legal requirements Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling behavior caused by non approved tires wheels Use only tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surface must be roughened in the first 200 kilometers 124 3 miles by moderate driving at alternating angles The full grip is not reached until the vehicle has been run in Warning Danger of accidents Brake system failure Ifthe foot brake pedal is not released the brake linings drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 1 _ e Info When using your vehicle remember that others may feel disturbed by excessive noise Make su
81. ofen Austria All rights reserved Reproduction even in part is permitted only with the express written permission of the copyright owner E ISO 9001 12 100 6061 Within the meaning of the international quality management standard ISO 9001 KTM uses quality assurance processes that TW lead to the maximum possible quality of the products Issued by TUV Management Service MECO IE 200 d06 KTM Sportmotorcycle AG 5230 Mattighofen Austria CONTENTS Uj a j MEANS OF REPRESENTATION ccccccccececcccececcececcececeuceceucecs 6 Setting the clock iioii ee a ed ce etd cbs 28 IMPORTANT NOTES cian 7 Combination instrument ODO display 29 VIEW OF VEHICLE iiio beer alii 12 Combination instrument setting resetting TRIP 1 display 29 View of vehicle front left side 12 Combination instrument setting resetting TRIP 2 display 30 View of vehicle rear right Side hL i ee 14 Combination instrument TRIP F display 31 LOCATION OF SERIAL NUMBERS ene 16 Combination instrument coolant temperature indicator 31 Chassis number type label ke 16 Opening filler caps n Esos a pe tata com ter in De hectare tend 32 Wane asinna ost ctetu tiM m ARMS a dcs m 16 Closing tiller Cap ee m l an C Les Le esaet ese Ned 32 Engine numit nii ken ar e a ono AT 17 Fuel lapse norecane na a ene nnne 33 Fork part number ssssssseee
82. ol Set ves RR RR RI hw nA uU 35 Transport 2 auis zz a AA Oe aes 8 Troubleshooting llle 126 128 Type label 2004 sano aur sme rine Sae ak aa a d 16 View of vehicle front TETE i cud ERES EA eds 12 rear right side 3211244en 2 G 11 2007 Photo Mitterbauer
83. onderful sport and we naturally hope that you will be able to enjoy it to the fullest However it is a potential problem for the environment and can lead to conflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of others In your own interest read the specified warning notes e 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 Danger A Danger that leads immediately and certainly to severe and permanent injury or death A Warning Danger that will probably lead to severe and permanent injury or death T Caution Danger that could possibly lead to slight injuries Note Danger of serious damage to machine or material Warning ae Risk of environmental damage Read this owner s manual carefully and completely before making your first trip It contains a lot of information and tips to help you operate and handle your motorcycle Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle __IMPORTANTNOTES gt
84. ording to the instructions on the battery casing Switch off the charger after charging Disconnect the battery Specification The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Position the fuel tank P 91 Mount the seat P 89 Set the clock P 28 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses MAINTENANCE WORK ON CHASSIS AND ENGINE gs e 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 100152 10 Switch off all power consuming components and switch off the engine Remove the seat P 89 Reinstall the fuel tank 7 P 90 Remove the protection cover Remove a defective main fuse with a needle nose plier Check parts for damage and wear Replace damaged or worn parts e info A reserve fuse is located in the starter relay Fit a new main fuse Fuse 58011109130 P 143 e Info If the new fuse burns out contact an authorized KTM workshop Replace the protection cover Position the fuel tank P 91 Mount the seat P 89 Set the clock P 28 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1 x Changing fuses of individual power co
85. ort 10 clicks 12 mm 0 47 in Spring rate Weight of rider 65 75 kg 143 165 Ib Weight of rider 75 85 kg 165 187 Ib Weight of rider 85 95 kg 187 209 Ib 60 N mm 343 Ib in 65 N mm 371 Ib in 70 N mm 400 Ib in Spring length 220 mm 8 66 in Gas pressure 12 bar 174 psi Static sag 27 mm 1 06 in Riding sag 60 65 mm 2 36 2 56 in Fitted length 380 mm 14 96 in Screw combination instrument holder 1 Nm 0 7 Ibf ft Screw side stand switch M4 2 Nm 1 5 Ibf ft Loctite 243 Spoke nipple front wheel 690 SUPER M4 5 5 Nm 3 7 Ibf ft MOTO Remaining screws chassis M5 4 Nm 3 Ibf ft Screw exhaust heat shield M5 5 Nm 3 7 Ibf ft Loctite 243 Screw pressure regulator Screw footbrake pedal foothold ann BFA 6 Nm 4 4 bf ft Loctite 243 Screw plastic clamp of brake line on M5 2 Nm 1 5 Ibf ft fork leg Screw fuel pump M5 4 Nm 3 Ibf ft Screw fuel level indicator al 3 Nm 2 2 Ibf ft Screw side cover M5 2 Nm 1 5 Ibf ft Screw seat lock M5 3 Nm 2 2 Ibf ft Loctite 222 Screw starter cable on starter M5 3 Nm 2 2 Ibf ft Spoke nipple rear wheel 690 SUPER M5 5 Nm 3 7 Ibf ft MOTO Remaining nuts chassis M6 15 Nm 11 1 Ibf ft Remaining screws on fuel tank M6 6 Nm 4 4 Ibf ft Remaining screws chassis Screw compensating tank o
86. port 10 clicks full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Compression damping of shock absorber 690 SUPERMOTO R The shock absorber can regulate compression damping in low and high speed range separately Dual Compression Control The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle The low and high speed technology works non specifically Adjusting the low speed compression damping of the shock absorber 690 SUPERMOTO R Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself e Info The low speed setting can be seen during the slow to normal compression of the shock absorber MAINTENANCE WORK ON CHASSIS AND ENGINE sy Turn the adjusting screw clockwise with a screwdriver until it stops e info Do not loosen nut Turn back counterclockwise the number of clicks corresponding to the shock absorber type Specification Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Adjusting high speed compression damping of the shock
87. pped baggage Check the way your baggage is fixed regularly Warning Danger of accidents After a fall check the vehicle After a fall check the vehicle as usual before putting it into operation Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear RIDING INSTRUCTIONS 1 a 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 radiator and top up if necessary If you continue with the coolant temperature warning lamp alight you may have engine failure e Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle e Info I For the positions of the 6 forward gears see the illustration The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 5 bars of the temperature indicator 100111 10 light up W
88. pump Starting aid Electric starter automatic decompressor Engine oil SAE 10W 60 P 153 Capacity coolant Coolant 1 201 1 27 qt Coolant P 152 Coolant mixed ready to use P 152 Plug oil bore Screw membrane fixation self tapping 9 Nm 6 6 Ibf ft 2 5 Nm 1 84 Ibf ft Loctite 243 Loctite 243 Oil jet conrod lubrication Hose clamp intake flange Screw cover plate for oil return line Ili Oi m m O 2 Nm 1 5 Ibf ft 1 5 Nm 1 11 Ibf ft 6 Nm 4 4 Ibf ft Loctite 243 Screw breather cover on valve cover M5 3 Nm 2 2 Ibf ft Loctite 243TM Screw gear sensor M5 5 Nm 3 7 Ibf ft Loctite 243 Screw clutch spring M5 6 Nm 4 4 Ibf ft Locking screw for bearing al 6 Nm 4 4 Ibf ft Loctite 648 Screw oil filter cover M5 6 Nm 4 4 Ibf ft Screw oil pump cover M5 6 Nm 4 4 Ibf ft Loctite 243 Oil jet piston cooling M6x0 75 4 Nm 3 Ibf ft Loctite 2437 Screw locking lever M 10 Nm 7 4 Ibf ft Loctite 243 Screw Autodecompression M6 4 Nm 2 2 3 Ibf ft Loctite 2437 Screw axial lock of camshaft M6 m 7 4 Ibf ft Loctite 243 Screw timing chain guide rail M6 Nm 7 4 Ibf ft Loctite 2437 Screw generator cover M6 Nm 7 4 Ibf ft Screw in generator cover chain shaft M6 Nm 7 4 Ibf ft Loctite 2437 through hole Screw igni
89. re 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 Before your first trip read the entire operating instructions carefully Get to know the operating elements adjust the basic position of clutch lever P 113 adjust the basic position of handbrake lever P 71 Adjust the basic position of the footbrake lever Get used to handling the vehicle on a car park before making a longer trip Try also to ride as slowly as possible and in a standing posi tion to get a better feeling for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not make any changes to the vehicle and use only KTM approved parts e Info Parts from other manufacturers can reduce the operational safety of the vehicle Run the engine in Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Specification Maximum engine speed During the first 1 000 km 621 4 mi 6 000 rpm After the first 1 000 km 621 4 mi 7 800 rpm GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 1 Avoid fully opening the throttle Loading the vehicle A A A A A A Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight con
90. res all have an important impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces Examine the tires for cuts foreign bodies and other damage Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth Minimum tread depth gt 2 mm gt 0 08 in If the minimum tread depth is insufficient Change the tires Checking tire air pressure e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove dust cap Check tire air pressure when tires are cold Tire air pressure road 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 100170 10 Rear 2 2 bar 32 psi Ifthe tire pressure does not meet specifications Correct tire pressure Mount dust cap MAINTENANCE WORK ON CHASSIS AND ENGINE amp amp Checking spoke tension 690 SUPERMOTO Warning Danger of accidents Unstable riding behavior due to loose spokes If you ride with loose spokes the spokes can break Have the spoke tension corrected in an authorized KTM workshop e Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too ti
91. sists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warning Danger of accidents Risk of breakage of suitcase system f you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage Ifthe tail light is covered you are less visible to following traffic especially in the dark Check the way your baggage is fixed regularly Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload Adapt your speed according to your payload GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 1 1 0 Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly 0 Warning Danger of burns A hot exhaust system can burn baggage Fasten
92. th the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a hard surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Turn the steering to the left press the ignition key down to the position amp and turn it to the position 8 To make locking the steering easier move the handlebar a little to the left and right Remove the ignition key RIDING INSTRUCTIONS 1 1 x3 Refueling Danger Fire hazard Fuel can easily catch fire 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 Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel 0 Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Warning RE Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground
93. the central position after use Flasher light right on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use Vt To switch off the flasher light press the flasher switch towards the switch case 500021 10 The horn button O is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position 500021 11 Ignition steering lock The ignition steering lock 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 the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 500019 01 The emergency OFF switch O is fitted on the left side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be started AO 500022 10 The electric starter button is fitted on the right side of the handlebar Possible stat
94. tion pulse generator M6 Loctite 243 Screw rocker arm shaft M6 Screw clutch cover M Screw clutch slave cylinder M6x20 Loctite 243 Screw clutch slave cylinder M6x35 Screw engine housing M6 Screw shift drum locating Oo 10 Nm 7 4 Ibf ft Loctite 243 Screw shift lever M6 Nm 7 4 Ibf ft Loctite 222 Screw timing chain tensioning rail M6 Nm 7 4 Ibf ft Loctite 243 Screw starter motor M6 Nm 7 4 Ibf ft Loctite 243 Screw thermostat housing M6 Nm 7 4 Ibf ft Loctite 243 Screw valve cover M6 Nm 7 4 Ibf ft Screw water pump cover M6 Nm 7 4 Ibf ft Screw water pump wheel M6 Nm 7 4 Ibf ft Loctite 2437 Screw cylinder head M6 10 Nm 7 4 Ibf ft Loctite 2437 Plug vacuum connection M6 10 Nm 7 4 Ibf ft Plug crankshaft location M8 20 Nm 14 8 Ibf ft Screw unlocking of timing chain ten M10x1 10 Nm 7 4 Ibf ft sioner Plug drain hole of water pump Plug oil bore for oil radiator Plug oil bore M10x1 M10x1 M10x1 1 5 Nm 11 1 Ibf ft 15 Nm 11 1 Ibf ft 15 Nm 11 1 Ibf ft Loctite 243 Screw cylinder head 15N Step 30N Step 45N Step 60N Tightening sequence Tighten diagonally beginning with the rear screw on the chain shaft Step 1 m 11 1 Ibf ft 2 m 22 1 Ibf ft 3 m 33 2 Ibf ft 4 m 44 3 Ibf ft Engine oil any
95. ug oil screen M20x1 5 15 Nm 11 1 Ibf ft Position oil screen with O rings Refit plug with O ring and tighten it Specification Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove filler plug with O ring from the clutch cover and add engine oil 1 701 1 8 qt Engine oil SAE 10W 60 P 153 Refit plug with O ring and tighten it Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level P 117 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove filler plug with O ring O from the clutch cover and add engine oil Engine oil SAE 10W 60 P 153 Refit plug with O ring and tighten it MAINTENANCE WORK ON CHASSIS AND ENGINE 1 wx Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level
96. up with engine oil V 123 TOPPING up engine oil j5i iEli ka y hall el be ka nera korek asa 124 TROUBEESHOQOTING eaat edes bove eb Red qt ine 126 FLASHING CODE urraca ertt eeu etes od 129 CLEANING caos 132 Cleaning motorcycle h h kh ll kk kk kk k 132 CONSERVATION FOR WINTER OPERATION M U 134 Conservation for winter operation h 134 STORAGE iid a OE ied reta ede d DE ded eas 135 STOKA S i initi recie sd Recreo deesset e a derk kay 135 Putting into operation after storage K A EKCElEE UU 136 TECHNICAL DATA ENGINE Mek kk k 137 Capacity engine oil oocccoccnccncccccccononcnnnnnonnnonnnoncnonanononos 138 Capacity coolant iis Lc aa edema 138 TECHNICAL DATA ENGINE TIGHTENING TORQUES 139 TECHNICAL DATA CHASSIS Ml kk 142 Lighting equipment ssssssssssee nemen 143 Capacity fuel ec dee E RJ MH DIXE 144 TECHNICAL DATA FOR Kur4 ikak lak xb z r xela a teeneline 145 TECHNICAL DATA SHOCK ABSORBER J 146 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 148 SUBSTANCES ehe eger etri eei enr edes ee ined os 152 AUXILIARY SUBSTANCES i nnn ane aaa 155 STANDARDS az a yey ds 157 INDEX 5 i d erste teet ro dette se mec m tet vae ian nedan 158 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 All work marked
97. usting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 690 SUPERMOTO Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw MAINTENANCE WORK ON CHASSIS AND ENGINE 33 m 690 SUPERMOTO R Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw 100116 10 Checking correcting fluid level of hydraulic clutch e Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 690 SUPERMOTO Remove screws Remove the cover with membrane 6 Check the fluid level Fluid level under top level of container 4 mm 0 16 in Ifthe fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 P 153 Check parts for damage and wear Replace damaged or worn parts MAINTENANCE WORK ON CHASSIS AND ENGINE 135 Position the cover with the membrane Mount and tighten screws 690 SUPERMOTO R Check the fluid level The fluid level must be between the MIN and MAX markings Ifthe fluid level does not meet specif
98. ustration Place a cloth 8 between the compensating tank and the spoiler to prevent damage al Y 100174 10 E Remove the cloth from between the compensating tank and the spoiler Carefully move the fuel tank forwards and lower it Mount and tighten the screw with the rubber bushing and bearing sleeve Check fuel tank for tight fitting Specification Screw fuel tank bracket MB 15 Nm 11 1 Ibf ft Check the routing of the fuel hoses Mount the seat P 89 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1 Removing the battery A A Warning Risk of injury Battery acid and battery gases cause serious cauterization 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 fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Remove the seat P 89 Reinstall the fuel tank P 90 Disconnect the negative minus cable of the battery Detach and remove the rubber band Take off the positive terminal cover O Disconnect the positive plus cable of the battery Pull the battery to the right out of the battery rack e Info I Never operate the motorcycle with a discharged battery or w
99. 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 components get very hot when the machine is driven Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them Note Danger of damage Danger of damage by the vehicle running away or falling over RIDING INSTRUCTIONS 1 1 1n s Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Brake the motorcycle Shift gear to neutral Turn the ignition key to the position amp Info e 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 engine wi
100. with contact spray Read the error memory with the KTM diagnostics tool and correct the fault Engine has too little power Air filter very dirty Have the air filter changed TROUBLESHOOTING J au Faults Engine has too little power Possible cause Fuel filter very dirty Defect in fuel injection system Measure Have the fuel filter changed Read the error memory with the KTM diagnostics tool and correct the fault Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level P 109 Radiator fins very dirty Foam formation in cooling system Buckled or damaged radiator hose Clean radiator fins Drain the coolant P 110 Fill bleed the cooling system P 111 Have the radiator hose changed Thermostat defective Have thermostat removed and checked Specification Opening temperature 70 C 158 F Fuse 5 blown Defect in radiator fan system Air in cooling system Change the fuses of individual power consumers P 97 Have the radiator fan system checked Fill bleed the cooling system 4 en P 111 Fl warning lamp MIL lights flashes Engine dies during the journey High oil consumption Defect in fuel injection system Lack of fuel Read the error memory with the KTM diagnostics tool and correct the fault Fill up with fuel P 51
101. x Moto Clean 900 Specification KTM recommends Motorex products Supplier Motorex Motorex Protect amp Shine 645 Specification KTM recommends Motorex products Supplier Motorex Motorex Moto Polish Specification KTM recommends Motorex products Supplier Motorex Motorex Accu Contact Specification KTM recommends Motorex products Supplier Motorex Motorex Joker 440 Universal Different technical development directions required a new specification for 4 stroke motorcycles 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 Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the oil as the engine The JASO MA Standard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos ity The viscosity describes only one property of oil and says nothing about quality A Antifreeze Checking a HRH HERE HE HHH E E HHHH i 106 B Baggage cz ski JI a ey l eek Ree piss 40 Battery TEINS c dre rer A L L oto A FRI utes 93 recharging 4 56 ow esu due ue der ee ae ge wk 93 re

Kenmore 790.9093 Range User Manual

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