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KTM 2016 690 DUKE User Manual

KTM 2016 690 DUKE
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OWNER'S MANUAL 2016
690 Duke
Art. no. 3213398en

Table of Contents

Questions and Answers:

KTM 2016 690 DUKE Specifications

General IconGeneral
Displacement690 cc
Bore x Stroke102 mm x 84.5 mm
Torque @ rpm6500 rpm
Compression Ratio12.7 : 1
StarterElectric starter
Transmission6-speed
Fuel SystemElectronic fuel injection
FrameChromium-Molybdenum steel trellis frame, powder coated
Rear SuspensionWP monoshock
Front Wheel3.50 x 17"
Rear Wheel5.00 x 17"
Front Tire120/70 ZR17
Rear Tire160/60 ZR 17
Seat Height835 mm
Fuel Tank Capacity14 l
Engine TypeSingle cylinder, 4-stroke
Power73 hp
Front SuspensionWP Ø 43 mm
Front BrakeBrembo four piston, radially bolted caliper, brake disc Ø 320 mm
Rear BrakeBrembo single piston, floating caliper, brake disc Ø 240 mm
ABSBosch 9M+ Two Channel ABS (disengageable)

Summary

DEAR KTM CUSTOMER

MEANS OF REPRESENTATION

Symbols used

Explains the meaning of various symbols used in the manual, like checks and warnings.

Formats used

Explains typographical formats like specific names, protected names, and brands.

SAFETY ADVICE

Use definition - intended use

Defines the intended use of KTM sport motorcycles for regular road operation only.

Safety advice

Emphasizes reading the manual and adhering to safety instructions for safe riding.

Degrees of risk and symbols

Explains the meaning of danger, warning, and note symbols used to indicate risks.

Overview of labels

Illustrates the location of important labels on the motorcycle with numbered pointers.

Reporting safety defects

Guides users on reporting vehicle defects to NHTSA and KTM North America.

Noise emission warranty

Details the warranty coverage for the exhaust system concerning U.S. EPA Federal noise standards.

Operating noise warning

Warns about checking motorcycle noise for potential penalties under local ordinances.

Consumer rights

Explains warranty claims submission and customer service contact information.

Tampering warning

Warns against tampering with the noise control system, citing federal laws and prohibited acts.

Safe operation

Covers essential safe operation practices, including warnings about alcohol and exhaust gas poisoning.

Protective clothing

Stresses the importance of wearing appropriate protective clothing for rider safety.

Work rules

Outlines general rules for performing work on the motorcycle, including tool use and part replacement.

Environment

Advises on responsible use and proper disposal of motorcycle-related fluids and components.

Owner's Manual

Emphasizes reading the Owner's Manual for operation, handling, and maintenance guidance.

IMPORTANT NOTES

Manufacturer and implied warranty

Explains warranty coverage, conditions, and the necessity of authorized workshop service.

Operating and auxiliary substances

Discusses safe handling and environmental impact of operating fluids like fuel.

Spare parts, accessories

Recommends using only approved spare parts and accessories for safety and liability reasons.

Service

Highlights the criticality of scheduled service and maintenance for vehicle performance and longevity.

Figures

Notes that manual figures may depict special equipment or disassembled parts for illustration.

VIEW OF VEHICLE

View of vehicle, front left side

Identifies and labels major parts of the motorcycle from the front left perspective.

Clutch lever

Identifies the clutch lever with its page reference for detailed information.

Seat

Identifies the seat with its page reference for detailed information.

Passenger seat

Identifies the passenger seat with its page reference for detailed information.

Handrails

Identifies the handrails with their page reference for detailed information.

Seat lock

Identifies the seat lock with its page reference for detailed information.

Side stand

Identifies the side stand with its page reference for detailed information.

Shift lever

Identifies the shift lever with its page reference for detailed information.

Engine number

Identifies the engine number with its page reference for detailed information.

View of vehicle, rear right side

Identifies and labels major parts of the motorcycle from the rear right perspective.

Tool set

Identifies the tool set with its page reference for detailed information.

Filler cap

Identifies the filler cap with its page reference for detailed information.

Light switch

Identifies the light switch with its page reference for detailed information.

Turn signal switch

Identifies the turn signal switch with its page reference for detailed information.

Horn button

Identifies the horn button with its page reference for detailed information.

Ignition/steering lock

Identifies the ignition/steering lock with its page reference for detailed information.

Emergency OFF switch

Identifies the emergency OFF switch with its page reference for detailed information.

Electric starter button

Identifies the electric starter button with its page reference for detailed information.

Hand brake lever

Identifies the hand brake lever with its page reference for detailed information.

Chassis number

Identifies the chassis number with its page reference for detailed information.

Fuse box

Identifies the fuse box with its page reference for detailed information.

Level viewer, engine oil

Identifies the engine oil level viewer with its page reference for detailed information.

Foot brake lever

Identifies the foot brake lever with its page reference for detailed information.

Passenger footrest

Identifies the passenger footrest with its page reference for detailed information.

SERIAL NUMBERS

Chassis number

Explains the location of the chassis number, typically stamped on the steering head.

Type label

Describes the location of the type labels, identifying the motorcycle's manufacturing details.

Key number

Guides on finding the key number on the KEYCODECARD for ordering replacement keys.

Engine number

Explains the location of the engine number on the engine casing, near the sprocket.

Fork part number

States that the fork part number is stamped on the inner side of the fork stub.

Shock absorber article number

Indicates the location of the shock absorber article number on the left side of the shock absorber.

CONTROLS

Clutch lever

Describes the clutch lever's location and its hydraulic, self-adjusting operation.

Hand brake lever

Describes the hand brake lever's location on the right handlebar for front brake engagement.

Throttle grip

Describes the throttle grip's location on the right handlebar.

Switches on the left side of the handlebar

Introduces controls located on the left handlebar, including combination switch, light, menu, and horn.

Switches on the right side of the handlebar

Introduces controls located on the right handlebar, including emergency OFF and starter buttons.

Emergency OFF switch

Explains the function of the emergency OFF switch for stopping the engine.

Electric starter button

Describes the function of the electric starter button for starting the engine.

Ignition/steering lock

Explains the ignition and steering lock functions and their possible states.

Opening the filler cap

Provides instructions and safety warnings for opening the fuel filler cap.

Closing the filler cap

Details the procedure for closing the fuel filler cap, including safety warnings.

Seat lock

Explains the location and operation of the seat lock, which can be used with the ignition key.

Tool set

Indicates that the tool set is located under the passenger seat.

Handrails

Describes the purpose of handrails for moving the motorcycle and for passenger grip.

Passenger footrest

Explains that passenger footrests are foldable and their states for solo or passenger operation.

Shift lever

Details the mounting location of the shift lever and shows gear positions.

Foot brake lever

Describes the location of the foot brake lever for rear brake engagement.

Side stand

Explains the location and function of the side stand for parking and its relation to the safety starting system.

COMBINATION INSTRUMENT

Overview

Provides an overview of the combination instrument, divided into indicator lamps and display areas.

Indicator lamps

Explains the meaning of various indicator lamps on the instrument cluster and their states.

Speed

Details how the speed is displayed in km/h or mph on the instrument cluster.

Time

Explains how the time is displayed and that it may need resetting after battery disconnection.

Temperature

Describes how the current ambient temperature is shown on the instrument cluster display.

Gear display

Explains that the current gear is shown on the instrument cluster display.

Fuel tank capacity

Details how the fuel tank contents are shown, with a warning for low fuel levels.

Coolant temperature indicator

Explains the 8-bar coolant temperature display and its different states.

"Favorites"

Describes how to access and configure the "Favorites" menu for quick access to frequently used functions.

"Trip 1"

Explains the "Trip 1" display, showing distance, average speed, fuel consumption, and trip time.

"Trip 2"

Explains the "Trip 2" display, showing distance, average speed, fuel consumption, and trip time.

"General info"

Describes the "General Info" display, showing air temp, date, ODO, battery voltage, and time.

"Set Favorites"

Details how to configure the "Set Favorites" menu to customize displayed menus for quick selection.

"Settings"

Explains the "Settings" menu for configuring units, values, and enabling/disabling functions.

"Warning"

Describes the "Warning" menu for displaying and storing active warnings and error messages.

"TC/ABS"

Explains how to switch TC and ABS on/off and select ABS modes like "Road" and "SupMot".

"MTC/ABS"

Explains how to switch MTC and ABS on/off and select ABS modes for R models.

"Language"

Describes how to change the display language in the settings menu.

"Distance"

Explains how to set the unit of measure for distance (km or miles) in the settings.

"Temp"

Explains how to set the unit of measure for temperature (°C or °F) in the settings.

"Pressure"

Explains how to set the unit of measure for pressure (bar or psi) in the settings.

"Volume"

Explains how to select the unit of measure for consumption displays in the settings.

Set the time and date

Provides a step-by-step guide to set the clock and date on the instrument cluster.

"Shift Light"

Explains the function and configuration of the Shift Light for gear shift recommendations.

"Extra functions"

Describes accessing and viewing optional extra functions available in the menu.

Drive Mode (optional)

Explains the Drive Mode selection (SPORT, STREET, RAIN) and its impact on engine and traction control.

PREPARING FOR USE

Advice on first use

Provides crucial advice for initial use, including safety warnings on impairment, clothing, tires, and brake system.

Running in the engine

Gives guidelines on engine break-in procedures, including maximum engine speeds for different mileage intervals.

Loading the vehicle

Details warnings and guidelines for loading the vehicle, covering weight limits and luggage placement.

RIDING INSTRUCTIONS

Performing checks and vehicle care when preparing for use

Lists essential pre-ride checks for vehicle roadworthiness and technical condition.

Starting

Explains the procedure for starting the engine, including safety warnings and notes on engine failure.

Starting off

Describes the procedure for moving off from a standstill, including clutch and throttle control.

Shifting, riding

Covers gear shifting techniques and general riding advice, with warnings on load changes and downshifting.

Warning Danger of accidents

Provides multiple warnings related to riding, including ignition key position, distractions, passenger safety, and tire grip.

Warning Danger of accidents

Continues warnings about riding conditions, including unstable handling, slipped baggage, and lack of roadworthiness.

Engine braking control (MSR)

Explains the function of the optional MSR system for preventing rear wheel lock-up during engine braking.

Applying the brakes

Details safe braking procedures, warnings about wet/dirty systems, spongy brakes, and ABS usage.

Warning Danger of accidents

Continues braking warnings regarding stopping distance, salted roads, ABS, and engine braking.

Stopping, parking

Provides instructions and warnings for safely stopping and parking the motorcycle.

Transport

Offers notes and guidelines for safely transporting the motorcycle, including securing it.

Refueling

Details the refueling process, including fire and poisoning hazards, and fuel specifications.

SERVICE SCHEDULE

Additional information

Notes that additional work must be ordered and invoiced separately.

Required work

Lists essential maintenance tasks required at specific mileage or time intervals.

Recommended work

Lists recommended maintenance tasks that are not strictly required but are advised for optimal performance.

TUNING THE CHASSIS

Adjusting the spring preload of the shock absorber

Explains how to adjust the rear shock absorber's spring preload for optimal ride behavior.

Adjusting the footrests

Details the procedure for adjusting the position of the rider's footrests.

SERVICE WORK ON THE CHASSIS

Raising the motorcycle with the rear lifting gear

Explains how to safely lift the motorcycle using rear lifting gear.

Removing the rear of the motorcycle from the lifting gear

Describes how to safely lower the motorcycle from the rear lifting gear.

Lifting the motorcycle with the front lifting gear

Details the preparatory and main steps for lifting the motorcycle using front lifting gear.

Taking the motorcycle from the front lifting gear

Explains how to safely remove the motorcycle from the front lifting gear.

Removing the passenger seat

Provides instructions on how to remove the passenger seat.

Mounting the passenger seat

Details the procedure for correctly mounting the passenger seat and checking its security.

Checking the chain for dirt

Explains how to check the drive chain for dirt and the need for cleaning if very dirty.

Cleaning the chain

Provides instructions for cleaning the drive chain, with warnings about oil on tires and brake discs.

Checking the chain tension

Explains how to check chain tension and the consequences of incorrect tension.

Adjusting the chain tension

Details the procedure for adjusting the drive chain tension, including wheel alignment.

Checking the chain, rear sprocket, and engine sprocket

Describes how to check the chain, rear sprocket, and engine sprocket for wear and when to replace the drivetrain kit.

Adjusting the basic position of the clutch lever

Explains how to adjust the clutch lever position for rider comfort and control.

Checking/correcting the fluid level of the hydraulic clutch

Details how to check and correct the hydraulic clutch fluid level, including safety warnings.

BRAKE SYSTEM

Antilock braking system (ABS)

Explains the ABS system, its components, warnings about modifications, and vehicle rollover risks.

Adjusting the basic position of the hand brake lever

Details how to adjust the hand brake lever position for rider preference and control.

Checking the brake discs

Explains how to check brake disc thickness, wear limits, and for damage like cracks or deformation.

Checking the brake fluid level of the front brake

Guides on checking the front brake fluid level, indicating potential leaks or worn linings.

Adding front brake fluid

Provides instructions for adding front brake fluid, with safety warnings and fluid type recommendations.

Checking the front brake linings

Explains how to check front brake lining thickness and the consequences of worn or damaged linings.

Checking the free travel of foot brake lever

Details how to check the free travel of the foot brake lever and adjust it if necessary.

Adjusting the basic position of the foot brake lever

Explains how to adjust the foot brake lever's basic position for optimal rider control.

Checking rear brake fluid level

Guides on checking the rear brake fluid level, warning of leaks or worn linings.

Adding rear brake fluid

Provides instructions for adding rear brake fluid, with safety warnings and fluid type recommendations.

Checking the rear brake linings

Explains how to check rear brake lining thickness and the consequences of worn or damaged linings.

WHEELS, TIRES

Removing the front wheel

Details the steps for safely removing the front wheel, including brake caliper and sensor handling.

Installing the front wheel

Provides instructions for installing the front wheel, including bearing checks and spacer placement.

Removing the rear wheel

Details the steps for safely removing the rear wheel, including chain and sensor handling.

Installing the rear wheel

Provides instructions for installing the rear wheel, including checks for hub dampers and brake operation.

Checking the rear hub rubber dampers

Explains how to check rear hub rubber dampers for wear and damage to prevent sprocket carrier damage.

Checking the tire condition

Covers checks for tire damage, tread depth, and age, with warnings about flat tires and handling.

Checking the tire pressure

Details how to check tire pressure when cold, for solo and loaded conditions, and warnings about low pressure.

ELECTRICAL SYSTEM

Removing the battery

Provides step-by-step instructions for safely removing the motorcycle battery, including warnings.

Installing the battery

Details the procedure for safely installing the motorcycle battery, including terminal connections.

Recharging the battery

Explains how to recharge the battery, including safety warnings and environmental considerations.

Changing the main fuse

Guides on how to change the main fuse, with warnings about electrical system overload.

Changing the ABS fuses

Details how to change ABS fuses for the hydraulic unit and return pump.

Changing the fuses of individual power consumers

Explains how to access and change fuses for various power consumers via the fuse box.

ELECTRICAL SYSTEM

Removing the headlight mask with the headlight

Details the steps for removing the headlight mask and its associated components.

Installing the headlight mask with the headlight

Provides instructions for installing the headlight mask and headlight assembly, and checking lighting.

Changing the headlight bulb

Guides on how to change the headlight bulb, with notes on reflector care.

Changing the parking light bulb

Details the procedure for changing the parking light bulb, with notes on reflector care.

Changing the turn signal bulb

Explains how to change the turn signal bulb, with notes on reflector care and proper installation.

Checking the headlight setting

Describes how to check the headlight alignment against specified marks on a wall.

Adjusting the headlight range

Explains how to adjust the headlight beam distance using a screw.

Diagnostics connector

Indicates the location of the diagnostics connector under the front rider's seat.

COOLING SYSTEM

Cooling system

Explains the function of the water pump, radiator cap, and compensating tank in regulating coolant circulation.

Checking the antifreeze and coolant level

Details how to check antifreeze protection and coolant level in the compensating tank, with safety warnings.

Checking the coolant level in the compensating tank

Explains how to check the coolant level in the compensating tank and add coolant if necessary.

Draining the coolant

Provides instructions for draining the engine coolant, including safety warnings.

Filling/bleeding the cooling system

Details the procedure for filling and bleeding the cooling system, with safety warnings.

TUNING THE ENGINE

Checking the basic position of the shift lever

Explains how to check the basic position of the shift lever for proper rider boot clearance.

Adjusting the basic position of the shift lever

Details the procedure for adjusting the shift lever's basic position for optimal gear shifting.

Drive Mode (optional)

Explains the selectable Drive Modes (SPORT, STREET, RAIN) and their performance characteristics.

Motorcycle traction control (optional) (MTC)

Describes the Motorcycle Traction Control system, its function, and control via menus.

SERVICE WORK ON THE ENGINE

Checking the engine oil level

Explains how to check the engine oil level at normal operating temperature and the correct level range.

Changing the engine oil and oil filter, cleaning the oil screens

Details the procedure for changing engine oil and filter, with warnings about hot oil and environmental hazards.

Adding engine oil

Provides instructions for adding engine oil, with warnings about low oil levels and mixing oils.

CLEANING, CARE

Cleaning the motorcycle

Details the process for cleaning the motorcycle, including water usage, cleaner types, and drying.

Checks and maintenance steps for winter operation

Provides steps for winter operation, including cleaning after road salt exposure and corrosion protection.

STORAGE

Storage

Lists actions to take before storing the motorcycle, such as refueling with additive, cleaning, and battery maintenance.

Preparing for use after storage

Details the steps required to prepare the motorcycle for use after it has been stored.

TROUBLESHOOTING

Engine does not crank when the electric starter button is pressed

Lists possible causes and actions for the electric starter button not engaging the engine.

Engine overheats

Lists possible causes and actions for the engine overheating, including coolant issues and radiator fins.

FI warning lamp (MIL) lights/flashes

Explains causes and actions for the FI (Malfunction Indicator) warning lamp.

N The idle indicator lamp does not light up when the transmission is in neutral

Addresses issues with the neutral indicator lamp not illuminating.

Engine dies during the trip

Lists possible causes and actions for the engine stopping unexpectedly during a ride.

The ABS warning lamp lights up

Explains causes for the ABS warning lamp illuminating, such as blown fuses or system malfunctions.

High oil consumption

Lists possible causes and actions for excessive engine oil consumption.

Headlight and parking light are not functioning

Addresses issues with headlights and parking lights not working, often related to blown fuses.

Turn signal, brake light, and horn are not functional

Lists causes and actions for non-functional turn signals, brake lights, or horn, typically fuse-related.

Time is not (correctly) displayed

Explains causes for incorrect time display, often linked to fuse issues or battery resets.

Battery discharged

Lists causes and actions for a discharged battery, such as ignition left on or charging issues.

Combination instrument shows nothing on the display

Addresses issues with the combination instrument display being blank, often due to blown fuses.

TECHNICAL DATA

Engine

Lists detailed specifications for the engine, including design, displacement, bore, stroke, and lubrication.

Engine tightening torques

Lists specific torque values for various engine screws and bolts, with recommended threadlockers.

Capacities

Specifies the required capacities for engine oil, coolant, and fuel.

Engine oil

Details the recommended engine oil types, grades, and capacities.

Coolant

Specifies the type and capacity of coolant required for the cooling system.

Fuel

States the total fuel tank capacity and the recommended fuel grade.

Chassis

Lists specifications for the motorcycle's chassis, including frame, fork, shock absorber, and brake system details.

Chassis tightening torques

Lists specific torque values for various chassis screws and bolts, with recommended threadlockers.

SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Details the standard classification, guidelines, and recommended suppliers for brake fluids.

Coolant

Outlines guidelines for coolant use, mixture ratios, and recommended suppliers.

Engine oil (SAE 10W/60)

Specifies standards, guidelines, and suppliers for SAE 10W/60 engine oil.

Engine oil (SAE 10W/50)

Specifies standards, guidelines, and suppliers for SAE 10W/50 engine oil.

Fork oil (SAE 4)

Details standards and guidelines for SAE 4 fork oil.

Super unleaded (ROZ 95/RON 95/PON 91)

Specifies the standard for unleaded super fuel and guidelines for its use, including ethanol content.

AUXILIARY SUBSTANCES

Chain cleaner

Lists recommended chain cleaner and its supplier.

Chain lube for road use

Lists recommended chain lube for road use and its supplier.

Fuel additive

Lists recommended fuel additive and its supplier.

Long-life grease

Lists recommended long-life grease and its supplier.

Motorcycle cleaner

Lists recommended motorcycle cleaner and its supplier.

STANDARDS

JASO T903 MA

Explains the JASO T903 MA standard for 4-stroke motorcycle oils, its purpose, and requirements.

SAE

Explains the SAE viscosity classification system for oils.

INDEX OF SPECIAL TERMS

LIST OF ABBREVIATIONS

LIST OF SYMBOLS

28.1 Red symbols

Explains red symbols indicating error conditions requiring immediate intervention.

28.2 Yellow and orange symbols

Explains yellow/orange symbols indicating prompt intervention and active driving aids.

28.3 Green and blue symbols

Explains green/blue symbols that reflect information.

N

Explains the meaning of the 'N' indicator lamp for neutral transmission.

High beam indicator

Explains the meaning of the high beam indicator lamp.

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