KTM 690 DUKE EU Packaging 4 2008 Manuel

SETUP INSTRUCTIONS 2008

Packaging4

690DUKEEU

690DUKEAUS/UK

690DUKEJP

690DUKEUSA

ART. NO. 3211338en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTMDEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop prudction of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes

that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

MEANS OF REPRESENTATION 2

1MEANS OF REPRESENTAT ION

Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained in the following.

Name Indicates a proprietary name.

Protected name®Identifies a protected name.

Trademark™ Identifies a brand in merchandise traffic.

SET‑UP 3

2SET‑UP

2.1Unpacking and setting up the vehicle

700211-01

–Remove the box and the plastic packaging.

Info

To avoid damaging the motorcycle when mounting the handlebar, do not

remove the plastic on the fuel tank until after all of the work has been com-

pleted.

–Check the vehicle for transport damage.

–Unpack the separate enclosure and check its contents on the basis of the enclosure

list.

700212-01

–Remove the operating elements from the transport holder. Remove the screws and

handlebar clamps. Remove the transport holder.

700213-01

–Position the operating elements on the right half of the handlebar.

–Position the handlebar.

–Position the handlebar clamps. Fit and slightly tighten the four screws.

100322-10

–Position the handlebar exactly.

The mark1of the scale on the handlebar should be in the center of the han-

dlebar clamp.

–Tighten the four screws evenly.

Guideline

Screw, handlebar clamp M8 20Nm

(14.8lbfft)

–Mount and tighten the right handlebar weight.

700214-01

–Position the operating elements on the left half of the handlebar.

Info

Position holding lugin bore.

700215-01

–Mount and tighten the rear mirror adapter and rear mirror on both sides.

–Position all operating elements exactly on the handlebar. Tighten all screws.

SET‑UP 4

700216-01

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Plier for footrest spring (58429083000)

700217-01

–Mount the reflector.

–Recharge the battery. ( S. 6)

–Stow away the tool set under the seat.

700211-01

–Remove the protective plastic.

–Carefully loosen and remove the tensioning belt over the link fork.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tensioning belts around the lower triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off of the palette.

–Fit the front spoiler. ( S. 8)

–Fill up with fuel. ( S. 8)

–Print out the current PDI form found on KTMDEALER.NET and perform the delivery

inspection.

–Set kilometers or miles. ( S. 7)

WORK 5

3WORK

3.1Removing the seat

700131-01

–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.

3.2Mounting the seat

700199-01

–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.

3.3Reinstalling the fuel tank

–Remove the seat. ( S. 5)

700159-01

–Remove screw.

Info

The fuel lines do not need to be disconnected.

700160-10

–Lay a 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 com-

pensating tank(see illustration). Place a clothbetween the compensating

tank and the spoiler to prevent damage.

3.4Positioning the fuel tank

700160-11

–Remove the clothfrom between the compensating tank and the spoiler.

WORK 6

700161-01

–Carefully move the fuel tank forwards and lower it.

–Mount and tighten screwwith bearing sleeveand rubber bushing. Check

fuel tank for tight fitting.

Guideline

Screw, fuel tank bracket M8 15Nm

(11.1lbfft)

–Check the routing of the fuel hoses.

–Mount the seat. ( S. 5)

3.5Recharging the battery

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.

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.

Warning

Environmental hazard Problem materials cause environmental damage.

–Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day.

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. ( S. 5)

–Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.

WORK 7

100151-10

–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

battery, and to test the generator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove the lid.

Charge the battery according to the instructionson the battery casing.

–Switch off the charger after charging. Disconnect the battery.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the

motorcycle is not in use.

3months

–Position the fuel tank. ( S. 5)

–Mount the seat. ( S. 5)

–Set the clock. ( S. 7)

3.6Setting the clock

Condition

The motorcycle is standing.

700115-10

–Switch on the ignition by turning the ignition key to the position 

(690DUKEUSA).

–Press theMODEbutton several times until theODO display mode is active.

–Keep theMODEbutton and theSETbutton pressed simultaneously.

The time begins to flash.

–Press theMODEbutton to adjust the hour.

–Press theSETbutton to adjust the minute.

–Keep theMODEbutton and theSETbutton pressed simultaneously.

The time is set.

3.7Setting kilometers or miles

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.

700120-01

–Switch on the ignition by turning the ignition key to the position 

(690DUKEUSA).

–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.

Guideline

Activation duration of MODEbutton 10s

WORK 8

3.8Fitting front spoiler

300028-01

–Position the front spoiler side parts to the center part and latch in.

–Fit the rubber grommets.

300026-10

–Position the front spoiler to the retaining bracket. Fit screwswith bushes, but

do not tighten yet.

Info

Do not forget the insulating washer on the retaining bracket.

300027-10

–Fit and tighten screwwith a flange adapter on both sides.

Guideline

Screw, bug spoiler M6 7Nm (5.2lbfft)

–Fully tighten screws.

Guideline

Screw, bug spoiler M6 7Nm (5.2lbfft)

3.9Refueling

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.

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 imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,

contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

Info

This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded

fuel only.

Ce manuel convient aux modèles suivants

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