KTM 690 User Manual

105 pages

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OWNER'S MANUAL 2008

690 Rally Factory Replica

ART. NO. 3211241en

Table of Contents4
Means of Representation6
Important Notes7
Location of Serial Numbers9
- Chassis Number9
- Type Label9
- Key Number9
- Engine Number9
- Fork Part Number9
- Shock Absorber Part Number10
Operating Elements11
- Clutch Lever11
- Hand Brake Lever11
- Short Circuit Button11
- Ignition Switch11
- Electric Starter Button11
- Light Switch12
- Horn12
- Flasher Switch12
- Overview of Indicator Lamps12
- Speedometer12
- Speedometer Activation and Test13
- Tripmaster Switch13
- Setting Kilometers or Miles13
- Setting the Clock14
- Adjusting Speedometer Functions14
- Querying Lap Time15
- Display Mode SPEED15
- Display Mode SPEED/H (Service Hours)15
- Display Mode SPEED / CLK (Time)16
- Display Mode SPEED/LAP (Lap Time)16
- Display Mode SPEED/ODO (Odometer)16
- Display Mode SPEED/TR1 (Trip Master 1)16
- Display Mode SPEED/TR2 (Trip Master 2)17
- Disply Mode SPEED/A1 (Average Speed 1)17
- Display Mode SPEED/A2 (Average Speed 2)17
- Display Mode SPEED/S1 (Stop Watch 1)18
- Display Mode SPEED/S2 (Stop Watch 2)18
- Fuses19
- Fuel Tank19
- Fuel Tap20
- Choke20
- Shift Lever21
- Foot Brake Pedal21
- Side Stand21
- Steering Lock22
- Locking the Steering22
- Unlocking the Steering22
- Tool Set22
- Handrail22
Tips and Hints on Putting into Operation23
- Advice on First Use23
- Running in the Engine24
Riding Instructions25
- Checks before Putting into Operation25
- Starting25
- Starting up26
- Shifting, Riding26
- Braking26
- Stopping, Parking27
- Refueling27
Greasing and Service Table29
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop29
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)30
- Important Checks and Maintenance Work to be Carried out by the Rider30
Maintenance Work on Chassis and Engine31
- Jacking up the Motorcycle31
- Removing the Motorcycle from the Work Stand31
- Checking the Basic Chassis Setting with the Rider's Weight31
- Compression Damping of Shock Absorber31
- Adjusting Compression Damping of Shock Absorber31
- Adjusting Rebound Damping of the Shock Absorber32
- Measuring Rear Wheel Sag Unloaded32
- Checking Static Sag of the Shock Absorber33
- Checking the Riding Sag of the Shock Absorber33
- Adjusting Spring Preload of the Shock Absorber33
- Adjusting Riding Sag34
- Removing the Shock Absorber34
- Installing Shock Absorber35
- Checking Basic Setting of Fork36
- Adjusting Compression Damping of Fork36
- Adjusting Rebound Damping of Fork36
- Bleeding Fork Legs37
- Cleaning Dust Boots of Fork Legs37
- Dismounting the Front Fender37
- Installing the Front Fender37
- Checking Play of Steering Head Bearing38
- Adjusting Play of Steering Head Bearing38
- Fork Offset39
- Handlebar Position40
- Adjusting Handlebar Position40
- Adjusting the Throttle Cables41
- Checking Chain Dirt41
- Cleaning the Chain41
- Checking the Chain Tension42
- Checking Rear Sprocket / Engine Sprocket for Wear42
- Adjusting Chain Tension42
- Adjusting Basic Setting of Clutch Lever43
- Checking Fluid Level of Hydraulic Clutch43
- Checking Front Brake Disc43
- Checking Free Play of Hand Brake Lever44
- Adjusting Free Travel of Handbrake Lever44
- Checking Front Brake Fluid Level44
- Topping up the Front Brake Fluid45
- Checking the Front Brake Linings45
- Removing Front Brake Linings46
- Mounting Front Brake Linings46
- Changing the Front Brake Linings47
- Checking Rear Brake Disc48
- Checking Free Play of Foot Brake Lever48
- Adjusting Free Travel of Foot Brake Pedal48
- Checking Rear Brake Fluid Level49
- Topping up Brake Fluid of Front Brake49
- Checking Rear Brake Linings50
- Removing Rear Brake Linings50
- Mounting Rear Brake Linings51
- Changing Rear Brake Linings51
- Removing Front Wheel52
- Fitting Front Wheel53
- Removing Rear Wheel53
- Fitting Rear Wheel54
- Tire Condition Checking55
- Checking Tire Air Pressure55
- Checking Spoke Tension56
- Removing the Trim56
- Mounting the Trim56
- Removing the Seat57
- Mounting the Seat57
- Removing the Front Fuel Tank57
- Installing the Fuel Tank58
- Folding up the Fuel Tank at the Rear58
- Lowering the Fuel Tank at the Rear59
- Removing the Motor Guard60
- Mounting the Motor Guard61
- Checking the Headlamp Setting61
- Adjusting the Headlamp62
- Removing the Battery62
- Installing the Battery63
- Recharging the Battery63
- Removing the Main Fuse64
- Fitting the Main Fuse64
- Checking the Coolant Level65
- Checking Coolant Level and Antifreeze65
- Removing the Air Filter66
- Installing the Air Filter66
- Cleaning Air Filter67
- Carburetor - Idle67
- Carburetor - Adjusting Idle68
- Checking Engine Oil Level69
- Changing Engine Oil and Oil Filter, Cleaning Oil Screen69
- Draining the Engine Oil69
- Removing the Oil Filter70
- Cleaning the Oil Screen71
- Mounting Oil Filter72
- Filling up with Engine Oil72
- Topping up Engine Oil73
Troubleshooting74
Cleaning76
- Cleaning Motorcycle76
Storage77
- Putting the Motorcycle into Operation after Storage77
Technical Data - Engine78
- Capacity- Engine Oil78
- Capacity - Cooling Liquid78
Technical Data - Engine Tightening Torques79
Technical Data - Carburetor81
- 690 Rally Factory Replica81
Technical Data - Chassis82
- Lighting Equipment82
- Tires83
- Capacity - Fuel83
Technical Data - Fork84
- Capacity - Fork Oil84
Technical Data - Shock Absorber85
Technical Data - Chassis Tightening Torques86
Wiring Diagram88
- Rally Factory Replica 1 of 388
- Rally Factory Replica 2 of 392

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KTM 690 Specifications

General

Engine Type	Single-cylinder, 4-stroke
Transmission	6-speed
Starter	Electric
Fuel System	Electronic fuel injection
Cooling	Liquid-cooled
Rear Suspension	WP monoshock
Front Brake	Single 320 mm disc, 4-piston caliper
Rear Brake	Brembo single-piston caliper, 240 mm disc
Fuel Tank Capacity	13.5 liters
Frame	Chromium-Molybdenum steel trellis
Rear Wheel	17"