KTM 690 Duke 2018 Manual

SETUP INSTRUCTIONS 2018

690 Duke

Art. no. 3213788en

INTRODUCTION

*3213788en*

3213788en

08/2017

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

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

changes in the interest 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 GmbH specifically 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 production of a particular

model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions,

misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the

regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission

of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assur-

ance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

690 Duke EU (F9703R4)

690 Duke US (F9775R3, F9775R4)

1 MEANS OF REPRESENTATION

1.1 Symbols used

The meaning of specific symbols is described below.

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

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

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

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Indicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

SETUP 2

2.1 Unpacking and setting up the vehicle

E00601-01

–Remove the box and the plastic packaging.

Info

To avoid damaging the motorcycle while mounting the

handlebar, leave the film on the fuel tank until all of

the work on the motorcycle has been finished.

–Check the vehicle for transport damage.

–Unpack the separate enclosure and check its contents on the

basis of the enclosure list.

(690 Duke US)

–Ensure that the reflector is mounted on the license plate

holder.

E00602-01

–Remove the controls from the transport holder. Remove the

screws and handlebar clamps. Remove the transport holder.

K00451-01

–Remove the right-hand handlebar weight.

–Position the controls on the right half of the handlebar.

Tighten the screws.

Guideline

Screw, throttle grip M5 3.5 Nm

(2.58 lbf ft)

E00174-10

Warning

Danger of accidents A repaired handlebar poses a

safety risk.

If the handlebar is bent or straightened, the mate-

rial becomes fatigued. The handlebar may break as a

result.

–Change the handlebar if the handlebar is damaged

or bent.

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount and tighten the screws

evenly.

2 SETUP

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

Info

The markings on the handlebar should be at the center

of the handlebar clamps.

Keep the gap widths equal when tightening.

–Mount and tighten the right handlebar weight.

–Check the throttle grip for smooth operation.

K00452-01

–Position the controls on the left half of the handlebar.

–Position all controls in their exact positions on the handlebar.

Tighten all screws.

M01519-01

–Mount and tighten the rear mirror adapter and rear mirror on

both sides.

H00385-01

–Mount the footrests with the springs and pins. Secure the pins

with the lock rings.

Footrest spring plier (58429083000)

F01045-10

–Mount reflector 1with spring washers 2on holding

plate 3.

–Mount the retaining plate on the license plate holder.

–Mount the license plate holder.

–Remove the protective film.

–Carefully loosen and remove the tension belt over the

swingarm.

Info

An assistant prevents the motorcycle from falling over.

SETUP 2

–Carefully loosen and remove the tension belts around the lower

triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off the pallet.

–Remove the radiator shield.

–Remove the passenger seat. ( p. 6)

–Remove the spare key and KEYCODECARD and keep in a safe

place for the handover.

–Secure the tool set with rubber holders under the passenger

seat.

Warning

Risk of injury Battery acid and battery gases cause

serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and safety

glasses.

–Avoid contact with battery acid and battery gases.

–Keep sparks or open flames away from the battery.

–Only charge batteries in well-ventilated rooms.

–Rinse the affected area immediately with plenty of

water in the event of contact with the skin.

–Rinse eyes with water for at least 15 minutes and

consult a doctor immediately if battery acid and

battery gases get into the eyes.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 6)

–Install the battery. ( p. 8)

–Refuel. ( p. 10)

–Check the headlight setting. ( p. 12)

–Prepare the vehicle according to the specifications in the

KTM Dealer.net for handover to the customer.

–Set the kilometers or miles. ( p. 10)

3 WORK

3.1 Removing the passenger seat

V00043-10

–Insert the ignition key in seat lock 1and turn it clockwise.

–Raise the rear of the passenger seat, push it towards the rear,

and remove it upward.

–Remove the ignition key from the seat lock.

3.2 Mounting the passenger seat

K00421-10

–Hook catches 1of the passenger seat onto the storage com-

partment, lower the rear, and simultaneously push forward.

–Press down the passenger seat until it clicks into place.

Warning

Danger of accidents The passenger seat can come

loose from the anchoring if it is not mounted correctly.

–After mounting the passenger seat, check that it is

locked correctly by pulling up.

–Finally, check that the passenger seat is correctly mounted.

3.3 Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and safety glasses.

–Avoid contact with battery acid and battery gases.

–Keep sparks or open flames away from the battery.

–Only charge batteries in well-ventilated rooms.

–Rinse the affected area immediately with plenty of water in the event of contact with the skin.

–Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and

battery gases get into the eyes.

Warning

Environmental hazard Batteries contain environmentally-hazardous materials.

–Do not dispose of batteries as household waste.

–Dispose of batteries at a collection point for used batteries.

Warning

Environmental hazard Hazardous substances cause environmental damage.

–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with

the applicable regulations.

WORK 3

Info

Even when there is no load on the battery, it discharges steadily.

The charging level and the method of charging are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the service life of the battery.

If the charging current, charging voltage, and charging time are exceeded, the battery will be destroyed.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sul-

fated, destroying the battery.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

Preparatory work

–Switch off the ignition by turning the ignition key to the posi-

tion .

–Remove the passenger seat. ( p. 6)

–Disconnect the negative cable of the battery. ( p. 8)

311910-10

Main work

–Connect the battery charger to the battery. Adjust the battery

charger.

EU battery charger XCharge-professional (00029095050)

Alternative 1

US battery charger XCharge-professional

(00029095051)

Alternative 2

UK battery charger XCharge-professional

(00029095052)

Alternative 3

CH battery charger XCharge-professional

(00029095053)

Info

Follow the instructions of the charger and the manual.

–Switch off the battery charger after charging and disconnect

from the battery.

Guideline

The charging current, charging voltage, and charging time

must not be exceeded.

Charge the battery regularly

when the motorcycle is not

in use

3 months

Finishing work

–Connect the negative cable of the battery. ( p. 9)

–Mount the passenger seat. ( p. 6)

–Set the time and date. ( p. 9)

3 WORK

3.4 Installing the battery

V00579-10

Main work

–Position the battery in the battery holder.

Battery (HTZ12A-BS)

The battery terminals face opposite the direction of travel.

–Reconnect rubber band 1.

–Connect both positive cables 2to the battery.

Guideline

Screw, battery termi-

nal

M6 2 Nm (1.5 lbf ft)

–Mount positive terminal cover 3.

V00580-11

–Connect negative cable 4to the battery.

Guideline

Screw, battery termi-

nal

M6 2 Nm (1.5 lbf ft)

Finishing work

–Mount the passenger seat. ( p. 6)

–Set the time and date. ( p. 9)

3.5 Disconnecting the negative cable of the battery

Preparatory work

–Switch off the ignition by turning the ignition key to the posi-

tion .

–Remove the passenger seat. ( p. 6)

V00580-10

Main work

–Disconnect negative cable 1of the battery.

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