OWNER'S MANUAL 2007 - Enduro Team

690 LC4 SUPERMOTO PRESTIGE690 LC4 SUPERMOTO

KTM Sportmotorcycle AG A–5230 Mattighofenwww.ktm.at

01/2007 FOTO: MITTERBAUERKTM Group Partner

ART. NR. 3.211.147 EN

OWNER’S MANUAL 2007

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All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices,colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items,all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liablefor any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equip-ment, which is not applied to standard models. © 2007 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG,Mattighofen only.

COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit:(a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorpo-

rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and(b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Frame number

Engine number

Key number

Stamp of dealer

INTRODUCTION »We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring youlots of fun and enjoyment, provided that you clean and maintain it appropriately.Please insert the serial numbers of your motorcycle in the boxes below:

In accordance with the international quality management ISO 9001 standard, KTM uses quality assuranceprocesses that lead to the highest possible product quality.

IMPORTANT INFORMATION » 2

INTENDED PURPOSE The 690 Supermoto / Prestige is designed and constructed for normal use on public roads but not for use on race courses or offroad terrain.

OWNER'S MANUALCarefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains use-ful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries. The Manual also con-tains important information on service and maintenance. In your own interest, pay particular attention to the information markedas follows:

– Ignoring these instructions, can endanger your body andyour life.

– Ignoring these instructions could cause damage to partsof your motorcycle or that the motor-cycle is not road-safeanymore.

The Owner's Manual corresponded to the latest information available for this model series at the time it was printed. Minor devia-tions resulting from enhancements to the motorcycle design cannot be entirely precluded. The Owner's Manual is an integral partof the motorcycle and must be handed over to the new owner when the motorcycle is sold.

SERVICEObservance of the service, maintenance and operating instructions for the engine and chassis specified in the Owner's Manual isa prerequisite for faultless operation and the avoidance of premature wear. Please observe the prescribed breaking-in periods, inspec-tion intervals and service intervals. Strict observance will significantly prolong the service life of your motorcycle.

Use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear oncomponents such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before theservice limit specified in the maintenance schedule has been reached.

IMPORTANT INFORMATION »WARRANTY The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop.This is the only place that has the qualified technicians and the special tools required for the 690 Supermoto / Prestige. Be sureto have the workshop verify all service work carried out in the service manual to avoid losing your right to claim under the warranty.The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to themotorcycle.

AUTOMOTIVE FLUIDS The fuels, lubricants and liquids specified in the Owner's Manual or automotive fluids with equivalent specifications must be usedin accordance with the maintenance schedule.

SPARE PARTS, ACCESSORIES For your own safety, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other productsor consequential damage resulting from the use of such products.

ENVIRONMENTMotorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potentialproblems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is usedresponsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, showthat you are environmentally conscious and respect the rights of others.

Enjoy driving your motorcycle !

KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

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INDEX » 4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .2INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .6

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .6Chassis number, type label . . . . . . . . . . . . . . . . . . . . . . . . .6

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . .7Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Clutch lever (690 Supermoto) . . . . . . . . . . . . . . . . . . . . . . .7Clutch lever (690 Supermoto Prestige) . . . . . . . . . . . . . . . .7Combined instrument display . . . . . . . . . . . . . . . . . . . . . .8Function buttons on combined instrument . . . . . . . . . . . . .8Combined instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Cooling liquid temperature display . . . . . . . . . . . . . . . . . .11Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Emergency OFF tip switch, starter tip switch . . . . . . . . . . .14Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . . .15Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . .18

Compression damping of fork (690 Supermoto Prestige) . . .18Rebound damping of shock absorber . . . . . . . . . . . . . . . . .19Damping action during compression of shock absorber (690 Supermoto Prest) . . . . . . . . . . . . . . . . . . . . . . . . . .19

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Instructions for initial operation . . . . . . . . . . . . . . . . . . . .20Running in the LC4 engine . . . . . . . . . . . . . . . . . . . . . . . .20Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . .21

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .22Check the following before each start . . . . . . . . . . . . . . . .22Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Fuel, refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .30MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .34

Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . .35Adjusting compression damping of fork (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .35Adjusting the fork and shock absorber . . . . . . . . . . . . . . .35Compression damping of shock absorber (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .36Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . . . . .37Adjusting rebound damping of shock absorber . . . . . . . . . .37Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . .38Correcting the chain tension . . . . . . . . . . . . . . . . . . . . . .38Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

INDEX » 5

Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . .39General information on KTM disk brakes . . . . . . . . . . . . . .40Checking the front brake fluid level (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .42Checking of brake fluid level - front brake (690 Supermoto) 42Changing the basic position of the handbrake lever . . . . . . .42Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .43Checking the rear brake fluid level . . . . . . . . . . . . . . . . . .44Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .44Dismounting and remounting the front wheel . . . . . . . . . .46Dismounting and mounting the rear wheel . . . . . . . . . . . . .48Checking the shock absorption rubbers in the rear hub . . . .50Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Fuses for individual power consumers . . . . . . . . . . . . . . . .55Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .56Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .57Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .57Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58Checking the cooling liquid level in the compensating tank .59Checking the cooling liquid level in the radiator . . . . . . . . .60Coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . .61Checking the oil level of the hydraulic clutch (690 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Changing the original position of the clutch lever . . . . . . . .62

Checking the oil level of the hydraulic clutch (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . .63Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . .63Checking and adjusting the throttle cable play . . . . . . . . . .64Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .65Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Changing the engine oil and the oil filter, cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .74STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .76TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .82HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84CONSUMER INFORMATION FOR USA ONLY . . . . . . . . . . . . .86

Chassis number, Type labelThe chassis number is stamped on the right side of the steering head tube. Enter this num-ber in the field on page no 1.The type label is located next to the chassis number.

Engine number, engine typeThe engine number and the engine type are stamped into the left side of the engine belowthe engine sprocket. Enter this number on page 1.

SERIAL NUMBER LOCATIONS » 6

Clutch lever (690 Supermoto)The clutch lever [1] is fitted on the left hand side of the handle bar. The adjusting screw [A]is used to change the original position of the clutch lever (see maintenance work on chassis and engine).The clutch is hydraulically actuated and adjusts itself automatically.

Hand brake leverThe hand brake lever [3] is mounted on the right side of the handlebar.The basic positionof the handbrake lever can be changed in 4 or 5 steps (see Maintenance work on chassisand engine).

OPERATION INSTRUMENTS » 7

Clutch lever (690 Supermoto Prestige)The clutch lever [2] is fitted on the left hand side of the handle bar. The adjusting screw[B] is used to change the original position of the clutch lever (see maintenance work onchassis and engine).The clutch is hydraulically actuated and adjusts itself automatically.


Combined instrument The combined instrument is divided into 4 parts. Function buttons: to select the display modes and basic settings in the displayTachometer: displays the engine speed Indicator lamps: provide additional information on the motorcycle operating condition Display: shows the speed, cooling liquid temperature, time, distance traveled

(ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2), distance traveledsince the reserve warning lamp went on (TRIP F)

Function buttons on combined instrument MODE [1]Briefly press the MODE button to go to the next display mode. The available display modesare distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2). The speed, cooling liquid temperature and time are always displayed.

SET [2]Press the SET button to reset trip master 1 or 2 to 0.

The 3rd button is not programmed.

Combined instrument display TEST When you switch on the ignition, all of the display elements will light up for 1 second forthe function test.

LENGTH The display will change for 1 second to display the circumference of the front wheel in mil-limeters. 1870 mm corresponds to a 17" front wheel.

Then the display will change back to the mode that was activated when the ignition wasswitched off.

9OPERATION INSTRUMENTS »SPEED [1]The speed can be displayed in kilometers per hour (km/h) or miles per hour (mph).

CHANGING THE SPEED DISPLAY FROM KM/H - MPH or MPH - KM/HSwitch on the ignition and press the MODE button more than 10 seconds in the ODO mode.

CLOCK [2]The dots between the hours and minutes will blink in the CLOCK display.The clock must be set if the battery was disconnected or if the fuse 2 was blown.

SETTING THE CLOCK Switch on the ignition and select the ODO mode. Press and hold the MODE button whileyou press the SET button more than 1 second. The time will start to blink. Use the MODE button to set the hours. Use the SET button to set the minutes.Then press the MODE and SET buttons simultaneously.

ODO [3]Displays the total kilometers or miles traveled.This figure will not be cleared if the battery is disconnected.


TRIP 1 [1]The trip meter 1 is always active and counts up to 999.9. It is used to measure the lengthof the trip or the distance between 2 refueling stops.

TO RESET TRIP 1 To reset the trip meter 1 to zero, switch on the ignition, select the TRIP 1 display mode andpress the SET button more than 2 seconds.

Press the MODE button to go to the next display mode.

TRIP 2 [2]The trip meter 2 is always active and counts up to 999.9. It is used just like TRIP 1.

TO RESET TRIP 2 To reset the trip meter 2 to zero, switch on the ignition, select the TRIP 2 display mode andpress the SET button more than 2 seconds.

Press the MODE button to go to the next display mode.

TRIP F [3]When the fuel level reaches the reserve mark, the display will automatically switch to TRIPF and begin to count (no matter which display mode was active before). At the same time,the fuel warning lamp will light up. You will still have enough reserve fuel for at least 30kilometers.After refueling, it will take approx. 3 minutes for the fuel lamp to go out, TRIP F to auto-matically reset to 0 and to return to the previous display mode.

NOTE:Press the SET button for 2 seconds to switch off the fuel warning lamp.


TachometerThe tachometer [3] shows the engine speed in revolutions per minute. Do not run the enginebeyond the orange mark at 7800 rpm.The speed limiter will set in at 8600 rpm, drastically reducing the engine power above thisrotational speed.

Cooling liquid temperature display The temperature display [1] is shown in 12 bars. The more bars that light up, the hotter thecooling liquid. When the upper bar lights up 115°C (239°F), all of the bars will start to blinkand the red warning lamp [2] will light up.

Possible causes for an increase in temperature, causing the red warning light for the cool-ing liquid temperature to light up:– Driving too slowly and driving with a heavy load at high air temperatures– Not enough cooling liquid in the system– The ventilator on the left radiator is not running– Improper use of the clutch when driving slowly


Indicator lampsThe green indicator lamp will blink in the blinker rhythm when the blinker isswitched on.NOTE: The indicator lamp will blink slower when a blinker is broken.

The green indicator lamp will light up when the gearbox is in an idling position.

The blue indicator lamp will light up when the high beams are switched on.

The red warning light will light up when the cooling liquid has reached a tempera-ture of approx. 115°C (239°F).

The orange warning lamp will light up when the fuel level has reached the reserve mark.At the same time the display will automatically change to TRIP F (see TRIP F).

The orange warning lamp (fuel injection) briefly lights up when the ignition is switchedon. It will go out when the gasoline pressure is high enough. If this warning lamp lights up while driving, a component in the injection system isdefective. The error can be identified by means of a blink code (see Trouble shooting).

The red warning lamp will light up if the voltage in the on-board electrics drops below10 volts. Immediately drive to the nearest authorized KTM workshop and have theelectrical system checked.


Ignition lockThe ignition lock has 3 switching positions.

Ignition off, (engine can't be started)

Ignition on, light on (engine can be started)

Ignition off, handlebar blocked

To switch the ignition to position turn the ignition key to position and firmly press itinto the lock. Turn the handlebar to the left, then turn the ignition key to the left.The ignition key can be withdrawn in position and .

Combination switchThe rocker switch LIGHTS [1] actuates the high beam or low beam.

High-beam light

Low-beam light

The light signal (high beam) is actuated with button [2].

The indicator switch [3] returns to central position after actuation. Press flasherswitch towards switch housing to switch off the flasher.

The horn is sounded with button [4].

Emergency OFF tip switch, starter tip switchThe emergency off switch [1] is provided for emergency situations and should not be usedto switch off the engine.The engine is ready for operation in position (ignition circuit and starter circuit are switchedon).The engine cannot be started in position (ignition circuit and starter circuit are interrupted).

Use the starter tip switch [2] to operate the electric starter.

Filler capThe filler cap [3] can be locked and is provided with a fuel evaporation control system.To open the cap insert the ignition key, turn it 90° counterclockwise, then lift off the fillercap.To close the tank insert the filler cap, turn the ignition key 90° clockwise and take out thekey.


Fuel taps2 fuel taps [4] are mounted on the fuel tank that must be open when the motorcycle is running. The level in the fuel tanks is equalized by means of a connecting hose.The fuel cocks only need to be closed to remove the tank.

Opening the fuel tap: Turn the knob all the way to the left.Closing the fuel tap: Turn the knob all the way to the right.

Seat lock, removing the seatThe seat lock [2] can be locked with the ignition key. To remove the seat, insert the ignition key and turn 45° in a counterclockwise direction. Liftthe seat in the back, pull back and lift off.

To mount the seat, attach the seat to the oval head screw [3], lower the seat in the backwhile sliding it towards the front. Both noses [4] should fit into the frame. Insert the catchbolts [5] in the lock housing and push the seat down in the back until you hear the catchbolts snap into place.Check whether the seat is correctly mounted.

If not correctly mounted, the seat can slip while you are driving and cause you to lose con-trol of your motorcycle.


GripsThe grips [1] are used to maneuver the motorcycle. If carrying a passenger, the passengercan hold on to the grip during the ride.


Owner's manual The vehicle comes with owner's manuals in several languages. Place the owner's manualissued in your language in the protective cover included in the scope of supply and fastenit under the seat (see photo).

Tool set The tool set [1] is located in the storage compartment under the seat.

Shift leverThe shift lever is mounted on the left side of the engine. The position of the gears is shownin the illustration. Neutral, or the idle speed, is located between first and second gear.


Side standFold the side stand [1] forward to the stop with your foot and put the weight of the motor-cycle on the stand. Make sure it is standing securely on a firm surface. The side stand islinked to the safety start system; follow the driving instructions.

Foot brake pedalThe foot brake pedal [2] is located in front of the right footrest. Its basic position can beadjusted to your seat position (see maintenance work).

FootrestsThe passenger footrests [3] fold up.


Compression damping of fork (690 Supermoto Prestige)The fork's damping action during compression travel (compression damping) can be adjusted.This allows you adjust the damping behavior to match your driving style and the payload.The adjusting screws [1] are located on the fork leg axle passage. More information is provided in the chapter "Adjusting the fork and shock absorber.“

Rebound damping of forkThe fork's damping action during rebound travel (rebound damping) can also be adjusted.This allows you adjust the damping behavior to match your driving style and the payload.The adjusting screws [2] are located on the upper end of the fork legs.More information is provided in the chapter "Adjusting the fork and shock absorber.“


Damping action during compression of shock absorber (690 Supermoto Prest)The shock absorber's damping action during compression travel (compression damping) canbe adjusted. This allows you adjust the shock absorber's damping behavior to match yourdriving style and the payload.The damping rate can be adjusted in the low and high-speed range (Dual Compression Control).The designation low and high-speed refers to the movement of the shock absorber and notto the motorcycle's driving speed.

The adjusting screw [1] for the low-speed range can be adjusted with a screwdriver.

The adjusting screw [2] for the high-speed range can be adjusted with a 15 mm socket wrench.

More information is provided in the chapter "Adjusting the fork and shock absorber.“

Rebound damping of shock absorberThe shock absorber's damping action during rebound travel (rebound damping) can also beadjusted. This allows you adjust the damping behavior to match your driving style and thepayload.The adjusting screw [3] is located on the bottom of the shock absorber.More information is provided in the chapter "Adjusting the fork and shock absorber.“

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » 20

Instructions for initial operation– Make sure the work for the „pre-delivery

inspection“ was performed by your author-ized KTM workshop. The DELIVERY CER-TIFICATE and SERVICE MANUAL willbe handed over when you pick up yourvehicle.

– Read these operating instructions care-fully before your first ride.

– Enter the chassis, engine and key num-bers on page 1.

– Familiarize yourself with the operatingelements.

– Adjust the clutch lever, the hand brakelever, the foot brake lever and the shiftlever in the position that is most conven-ient for you.

– This motorcycle is equipped with a three-way catalytic converter. Leaded fuel willdestroy the converter. Always use unleadedfuel.

– Get used to handling the motorcycle onan empty parking lot, before starting ona longer drive. Also try to drive as slowlyas possible and in standing position, toimprove your feeling for the vehicle.

– Hold the handlebars with both handsand leave your feet on the foot rests whiledriving.

– Remove your foot from the foot brakelever when you are not braking. If the footbrake lever is not released the brake padsrub continuously and the braking systemis overheated.

– Do not make any alterations to the motor-cycle and always use ORIGINAL KTM

SPARE PARTS. Spare parts from othermanufacturers can impair the safety ofthe motorcycle.

– New tires have a smooth surface, whichmeans that they must be run in to achievefull grip. For this purpose, ride the motor-cycle carefully at moderate speed duringthe first 200 kilometers with new tires,tilting the vehicle at different angles sothat all sections are properly roughened.Tires will not display their full grip char-acteristics until they are properly run in.

– Motorcycles are sensitive to changes inthe weight distribution. Read the sectionon „Accessories and payload“ when car-rying luggage.

– Pay attention to running-in procedure.

Running in the LC4 engineEven finely machined surfaces of engineparts have rougher surfaces than parts thatslide on each other for a long time. Therefore,every engine must be run in. For this reason,do not demand maximum performance fromthe engine for the first 1000 kilometers (620miles). The vehicle must be run in at low,changing performance level for the first 1000km (620 miles). The maximum number ofrevolutions per minute must not go exceed6000 rpm. Once you have run your enginein for 1000 km, you may push it to its 7800rpm limit , i.e. up to the orange zone indi-cated in the tachometer. Exceeding the abovelisted rotations as well as pushing high rpm

when the engine is cold will have an adverseeffect on the life of your engine.

– Wear suitable clothing when driving amotorcycle. Clever KTM drivers alwayswear a helmet, boots, gloves and a jacket,regardless of whether driving all day orjust for a short trip. The protective cloth-ing should be brightly colored so thatother vehicle can see you as early aspossible. Your passenger will also needsuitable protective clothing.

– Do not drive after having consumed alcohol.

– Drive at a moderate speed for the first fewkilometers of each trip to allow the tiresto reach the necessary operating temper-ature. Maximum road grip is assured whenthe tires are warm.

– The front and rear wheel are allowed tobe fitted only with tires that have thesame profile type.

– The tires must be designed for a maximum speed of 210 KPH (speed sym-bol H) and must be authorized by KTM.

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » 21

– New tires have a smooth surface, whichmeans that they must be run in to achievefull grip. For this purpose, ride the motor-cycle carefully at moderate speed duringthe first 200 kilometers with new tires,tilting the vehicle at different angles sothat all sections are properly roughened.Tires will not display their full grip char-acteristics until they are properly run in.

– Wheels with a different rim diameter orother rim width may not be mounted oth-erwise the vehicle handling will no longerbe safe.

– Observe the traffic regulations, drivedefensively and trying to look ahead asfar as possible so that any hazards canbe recognized as early as possible.

– The faster you drive, the more sensitiveyour motorcycle will be to crosswind andchanging road conditions. Your motorcy-cle can easily go out of control at highspeeds.

– Choose your driving speed according tothe conditions and your driving skills.

– Drive carefully on unknown roads or onunfamiliar trials.

– Renew the vizor on your helmet on timeso as to ensure optimum vision in any sit-uation. When light shines directly onscratched visor, the operator will beblinded.

– A passenger may only ride on the motor-cycle if passenger footrests are mounted.

– Never leave your motorcycle without super-vision if the engine is running.

Accessories and payloadAccessory parts and baggage can signifi-cantly decrease a motorcycle's driving stabil-ity. Please observe the following warnings.

– Never drive faster than 130 kph (80 mph)if you have mounted accessory parts onyour motorcycle. Accessory parts can sig-nificantly impair the motorcycle's han-dling, especially in the maximum speedrange.

– Never drive faster than 130 kph (80 mph)if your motorcycle is loaded with casesor other baggage. They will impair themotorcycle's handling at higher speeds andcan easily cause it to go out of control

– If you have cases mounted, do not exceedthe manufacturer's recommended maxi-mum payload.

– Make sure your luggage does not extendbeyond the silencer, otherwise it maybecome singed from the heat.

– Make sure your luggage does not coverthe tail light.

– Baggage must be securely and adequatelyfastenend; loose baggage will significantlyimpair driving safety.

– A high payload will change the motorcy-cle's handling and considerably increasethe braking distance; adapt your drivingspeed accordingly.

– Never exceed the maximum permissibleladen weight and the axle weights. Themaximum permissible laden weight ismade up of the following components:– Motorcycle ready for operation and tank

full– Luggage– Driver and passenger with protective

clothing and helmet

22DRIVING INSTRUCTIONS »Check the following before each startWhen you start, the motorcycle must be in perfect mechanical condition. For safety reasons,you should make a habit of performing an overall check of your motorcycle before each start.

The following checks should be performed:

1 FUELCheck the fuel quantity in the tanks.

2 CHAINCheck the tension and condition of the chain. A loose chain can fall off the sprockets and a worn-out chain can tear. In both cases thiscan damage other motorcycle components and cause the motorcycle to go out of control. A chain that is too tight or not greased will cause unnecessary wear to the chainand sprockets.

3 TIRESCheck for damaged tires. Tires showing cuts or dents must be replaced. The tread depthmust comply with the legal regulations. Also check the air pressure. Insufficient treadand incorrect air pressure deteriorate the driving performance.

4 BRAKESCheck correct functioning of the braking system. Check for sufficient brake fluid in thereservoir. The reservoirs have been designed in such a way that brake fluid does not needto be refilled even when the brake pads are worn. If the level of brake fluid falls belowthe minimum value, this indicates a leak in the braking system or completely worn outbrake pads. Arrange for the braking system to be checked by a KTM specialist, as com-plete failure of the braking system can be avoided.Also check the state of the brake hose and the thickness of the brake linings.Check free travel at hand brake lever and foot brake lever.

23

5 CABLESCheck the throttle cable for correct adjustment and smooth operation.

6 COOLING FLUIDCheck the level of cooling fluid when the engine is cold.

7 ELECTRICAL SYSTEMStart the engine and check the headlight, tail lamp, brake light, turn signals, indicatorlamps, horn and emergency-off switch for proper functioning.

8 CHECK OIL LEVELInsufficient oil results in premature wear and consequently to engine damage.

9 BAGGAGE, PAYLOADNever exceed the maximum total weight (350 kg, 773 lbs) and the motorcycle's wheelloads. The maximum total weight is comprised of:– the motorcycle in a running condition and refueled (164 kg, 362 lbs)– the baggage and accessories– the driver and passenger with protective gear and helmetAdapt the tire air pressure and the damping properties of the fork and shock absorberto the motorcycle's total weight.Make sure your luggage is correctly fastened before you drive off.

10 REAR MIRRORSit on the motorcycle and check the adjustment of the rear mirror.

DRIVING INSTRUCTIONS »

DRIVING INSTRUCTIONS » 24

Starting the engine1 Switch on emergency OFF switch [1].2 Switch on ignition (turn ignition key [2] into position ).

NOTE:You will hear the operation of the fuel pump for approx. 2 seconds after switching onthe ignition. The instrument cluster function test is also performed at this time.

3 Switch transmission to idle (green indicator lamp N [3] lights up).4 Do not accelerate; operate starter button [4]. Do not actuate the starter control until the

instrument cluster function test is completed.5 Take the load off the side stand and fold the side stand all the way up.

– Do not start the engine and allow it to idle in a closed room. Exhaust fumes are poison-ous and can cause loss of consciousness and death. Always provide adequate ventila-tion while the engine is running.

– Never operate the motorcycle with a run-down battery or without the battery. This candamage the electronic components or safety equipment in either caseand the motorcy-cle will no longer be roadworthy.

– If you accelerate while starting, the engine management will not inject any fuel and theengine will not start. Do not accelerate while starting!

– Maximum period for continuous starting: 5 seconds. Wait at least 5 seconds before try-ing again.

– Don’t ride your motorcycle with full load and don’t rev engine when cold. Because thepiston is warming up faster than the water cooled cylinder, it can cause engine damage.Always let the engine warm up before and refrain from driving with full load until theengine is warm.


IF THE ENGINE IS DOES NOT CRANK WHENYOU ACTUATE THE STARTER TIP SWITCH:– the transmission is switched to idle– Check if the emergency OFF switch is on– Check if the ignition is on– the headlight is on

– If this is not the case, the battery is dis-charged

– If the lights are on, proceed as describedin the „Trouble-shooting“ section orcontact a KTM dealer.

IF THE ENGINE CRANKS BUT DOES NOTSTART, WHEN YOU ACTUATE THE STARTERTIP SWITCH:– whether you accelerated while starting – whether the FI indicator lamp is blinking

– if yes, check Troubleshooting - Blinkcodes table

– Check if sufficient fuel is in the tank– If this is not the case, refill the tank– if sufficient fuel is in the tank, pro-

ceed as described in the „Trouble-shooting“ section or contact a KTMdealer.

NOTE:This motorcycle is equipped with a safety start-ing system. The engine can only be startedif the transmission is in neutral or the clutchlever is pulled. If the side stand is folded down,the engine can only be started if the trans-mission is in neutral or the clutch lever ispulled. The engine will stall if a gear is

engaged and the clutch lever is released withthe side stand folded down.

Starting offPull the clutch lever and engage 1st gear.Slowly release the clutch lever while you gen-tly accelerate.

Shifting/RidingYou are now in first gear, refered to as thedrive or uphill gear. Depending on the con-ditions (traffic, road gradient, etc.), you canshift to a higher gear. Close throttle, at thesame time pull clutch lever and shift to thenext higher gear. Let clutch lever go againand carefully open throttle. Do not shift gearsand accelerate carefully in curves.Only accelerate to the extent that road andweather conditions allow. Be especially care-ful when you accelerate in curves. Abruptopening of the throttle can cause the motor-cycle to go out of control and also increasesfuel consumption.By shifting down, use the brakes if neces-sary and close throttle at the same time. Pullclutch lever and shift down to the next gear.Let clutch lever go slowely and open throt-tle or shift down again.If the engine is killed f.ex. at a crossing, sim-ply pull the clutch lever and start. It is notnecessary to switch the gear to NEUTRAL.

Stop immediately if the FI indicator lamp lightsup while driving. The FI indicator lamp willstart blinking as soon as the transmission isin neutral. The rhythm of the blinking lampwill let you determine the two-digit „blinkcode“, e.g.: Blink code 24: FI blinks 2x long, 4x short,pause, Blink code 06: FI blinks 6x short, pause The blink code will indicate which compo-nent is defective (see Troubleshooting). Thismakes it possible to pinpoint the defect if adiagnostic tool is unavailable.

– Avoid abrupt load changes while ridingaround bends and on wet or slipperyground. Otherwise you might easily losecontrol over your motorcycle.

– While riding your motorcycle, never switchthe ignition lock to positions and .

– Do not try to change the settingsof thecombined instrument while driving. Yourattention will be distracted from the traf-fic and this may cause you to lose con-trol of your motorcycle.

– The passenger must hold on to the driveror the grab handles during the ride andkeep his feet on the passenger footrests.

– Regularly make sure that the baggageand cases are tightly fastened.


– After falling with the motorcycle, checkall functions thoroughly before starting upoperations again.

– A bent handlebar must always be replaced.Never try to straighten the handlebarbecause this will cause it to lose its stability.

– High rpm rates when the engine is coldhave an adverse effect on the life of yourengine. We recommend you run the enginein a moderate rpm range for a few milesgiving it a chance to warm up. After thatno further precautions in this respectneed be taken. The engine has reachedoperating temperature as soon as the 5thbar on the temperature indicator lights up.

– Never have the throttle wide open whenchanging down to a lower gear. The enginewill overspeed, damaging the valves. Inaddition, the rear wheel blocks so that themotorcycle can easily get out of control.

– Never use your motorcycle without an airfilter. Otherwise dust and dirt may enterthe engine and cause increased wear.

– The red coolant warning lamp lights upwhen the coolant temperature has reached115°C (239°F).Possible causes for the increase in tem-perature:– low driving velocity and high load

situation in high air temperatures

– level of coolant in the system is insuf-ficient

– fan at radiator is not running– improper use of the clutch while driving

at low velocitiesLet the engine cool down. Meanwhile,check whether any cooling liquid is leak-ing out of the motorcycle. Check the cool-ing liquid level in the radiator (not onlyin the compensating tank). - CAUTIONSCALDING HAZARD! Do not drive on,until there is sufficient liquid in the coling system.

– In the event that, while riding on yourmotorcycle, you notice any unusual oper-ation-related noise, stop immediately,turn the engine off, and contact an author-ized KTM dealer.

BrakingClose throttle and apply the hand and footbrakes at the same time. Carefully apply thebrakes on sandy, wet or slippery surfaces.Always brake with feeling, blocking wheelscan cause you to skid or fall. Also change downto lower gears depending on your speed.Always finish braking before you enter acurve.When driving downhill, use the braking effectof the engine. Change down one or two gearsbut do not overspeed the engine. In this way,you will not need to brake so much and thebrakes will not overheat.

– In the rain, or after the motorcycle hasbeen washed, braking action may bedelayed due to wet brake discs. First, thebrakes must be braked dry.

– On salt-sprayed or dirty roads brake actionmay be delayed as well. First, the brakesmust be braked clean.

– Remember that the stopping distancewill be longer if you are carrying a pas-senger or baggage.

– When you brake, the brake discs, brakepads, brake caliper and brake fluid heatup. The hotter these parts get, the weakerthe braking effect. In extreme cases, theentire braking system can fail.

– If the resistance in the hand brake leveror foot brake pedal feels „spongy“ (toomuch play), this is an indication thatsomething is wrong with the brake sys-tem. Don’t ride your motorcycle anymorewithout first having the brake systemlooked over by a KTM dealer.


Stopping and parkingApply the brakes fully and put the engine into neutral. To stop the engine, switch off theignition. Fold the side stand forward to the stop with your foot, put the weight of the motor-cycle on the stand and park the bike on a firm surface. Lock the motorcycle.

– always park your motorbike on a solid and horizontal surface.– Never leave your motorcycle without supervision as long as the engine is running.– Motorcycle engines produce a great amount of heat while running. The engine radiators,

exhaust, exhaust system, brake discs, and shock absorbers can become very hot. Do nottouch any of these parts after operating the motorcycle, and take care to park it wherepedestrians are not likely to touch it and get burned

– Never park your motorcycle in places where there exist fire hazards due to dry grass orother easily flammable materials.

– Always take out the ignition key when parking your motorcycle so that it cannot be usedby unauthorized persons.

– The side stand is designed to hold the weight of the motorcycle only. By sitting on themotorcycle, you will put additional weight on the side stand, possibly causing the sidestand or frame to be damaged or the motorcycle to fall down.


Fuel, refuelingThe LC4 engine requires unleaded fuel with at least RON 95 (USA = Premium PON 91, seetechnical specifications engine).

This motorcycle is equipped with a catalytic converter that will be destroyed if you use leadedfuel. Always use unleaded fuel.

Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).When you close the filler cap, make sure it is correctly positioned.

NOTE:After refueling, it will take approx. 3 minutes for the fuel warning lamp [1] to switch off andfor TRIP F to automatically reset to 0 and return to the previous display mode. Press theSET key [2] for 2 seconds to immediately turn off the fuel warning lamp.

Gasoline is highly flammable and poisonous. Extreme caution should be used when han-dling gasoline. Do not refuel the motorcycle near open flames or burning cigarettes. Alwaysswitch off the engine before refuelling. Be careful not to spill gasoline on the engine or exhaustpipe while the engine is hot. Wipe up spills promptly. If gasoline is swallowed or splashedin the eyes, seek a doctor’s advice immediately.

PERIODIC MAINTENANCE SCHEDULE » 30

690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007A clean motorcycle can be checked more quickly which saves money!

1st Serviceafter

1000 km(621 miles)

every5000 km

(3107 miles) oronce a year

every10000 km

(6214 miles) orevery 2 years

ENGI

NE

Change engine oil, coarse and fine filter

Clean oil screens and drain plug magnet

Renew spark plug

Check and adjust valve clearance

Check engine fastening bolts for tight fit

Check all engine bolts accessible from the outside for tight fit

FUEL

INJE

CTIO

N

Check rubber boots for cracks or leaks

Check fault memory with the KTM diagnosis tool

Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switchusing the KTM diagnosis toolMake sure the fuel hose, SAS hoses and vent hoses are run correctly andcheck for damage

Replace the O-ring on the fuel hose connection and check for leaks

Check the wiring harness on the throttle body for proper installationand damage

ADD-

ON-P

ARTS

Check cooling system for leaks and antifreeze protection

Check radiator fan for proper operation

Check the exhaust system for leaks and correct suspension and the clampsfor a tight fit

Check actuating cables for damage, smooth operation, and kink-less arrange-ment, adjust and lubricate

Check the oil level in the hydraulic clutch reservoir

Check air filter, renew if necessary, clean air filter box

Check cables for damage and kink-less arrangement



1st Serviceafter

1000 km(621 miles)

every5000 km


every10000 km


ADD-

ON-P

ARTS Check headlamp adjustment

Check electrical system for function (low/high beams, stop light, turn indica-tors, headlamp, flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch)

Make sure all bolts and nuts are tight

BRAK

ES

Check brake fluid level, lining thickness, and brake discs

Change brake fluid

Check brake lines for damage and leaks

Check/adjust smooth operation, free travel of handbrake/footbrake levers

Check bolts of brake system for tight fit

CHAS

SIS

Check shock absorber and fork for leaks and proper operation

Clean fork dust sleeves

Bleed fork legs

Check swinging-fork pivot

Check/adjust steering-head bearing

Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts,swinging-fork pivot, reversing lever, shock absorber)

Lubricate PRO-LEVER relay lever


IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM (3107 MILES) SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE!Service intervalls should never be exceeded by more than 500 km (311 miles).Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver!


1st Serviceafter

1000 km(621 miles)

every5000 km


every10000 km


WH

EELS

Check rim joint

Check tire condition and inflation pressure

Check chain, sprockets and chain guides for wear, force fit and tension

Check bolts on pinion and chain sprocket for locking devicesand a tight fit

Lubricate chain

Check wheel bearings and jerk damper for play

690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER

at leastonce a year

every 10000 km (6214 miles) or every 2 years

Perform complete fork maintenance

Perform complete shock absorber maintenance

Clean and lubricate steering-head bearing and sealing elements

Treat the electrical contacts and switches with contact spray

Treat battery connections with contact grease

Change coolant fluid


690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC

beforeeach start

afterevery cleaning

every 1000 km (621 miles)

Check oil level

Check brake fluid level

Check brake pads for wear

Check lighting system for proper operation

Check horn for proper operation

Lubricate actuating cables and nipples

Bleed fork legs

Clean chain

Lubricate chain

Check chain tension

Check tire pressure and wear

Check coolant level

Check fuel lines for leaks

Check all control elements for smooth running

Grease the hand brake lever and clutch lever

Check brake performance

Treat exposed metal components (except for the braking and exhaustsystem) with wax-based anti-corrosion agents

Treat ignition/steering lock and light switch with contact spray

MAINTENANCE WORK ON CHASSIS AND ENGINE » 34

– Do not clean the motorcycle with a power washer otherwise water will get into the bearings, electric socket connectors, etc. – Use special KTM screws with the correct thread length to fasten the spoiler to the tank. Mounting other screws or longer screws could

puncture the tank and cause fuel to leak out.– If you disconnect socket connectors with self-locking nuts, replace them before remounting. If no new self-locking nuts are available,

apply Loctite 243 to the thread of the old nuts. If the thread is damaged, replace the screws and nuts.– Do not use toothed disks or split washers for the engine fastening bolts since they will work their way into the frame components and

become loose. Always use self-locking nuts. – Let the motorcycle cool down before servicing to avoid being burned. – Properly dispose of oils grease, filters, fuel, cleansers, etc. Observe the regulations effective in your country.– Never pour used oil in the sewer or dispose of it outdoors. 1 liter of used oil will pollute 1,000,000 liters of water.

35

Adjusting the fork and shock absorber There are a number of ways to adjust the fork and shock absorber to match the chassis toyour driving style and the payload.We have provided a table with pragmatical values to help you tune up your motorcycle. Thesetune-up specifications are reference values only and should serve as a basis for your per-sonal chassis and suspension tuning. Do not make arbitrary changes to the settings (maxi-mum ±40%) since this may impair the handling characteristics (particularly in the high-speed range).Make sure both fork legs are equally adjusted.

Adjusting compression damping of fork (690 Supermoto Prestige)Hydraulic compression damping determines the reaction when the fork is compressed.Turn the adjusting screws clockwise to increase damping, turn it counterclockwise to reducedamping during compression. Make the same damping rate adjustment to both fork legs.

STANDARD ADJUSTMENT– Turn adjusting screw clockwise as far as it will go.– Turn 15 clicks in a counterclockwise direction.

MAINTENANCE WORK ON CHASSIS AND ENGINE »

BASIC SETTINGFORK WP 4860 ROMA

Supermoto Supermoto Prestige

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Compression adjuster (clicks) - - - - 20 15 10 10

Rebound adjuster (clicks) 20 15 10 10 20 15 10 10

Adjusting rebound damping of forkHydraulic rebound damping determines the reaction when the fork is rebound. By turningthe adjusting screw [1] (REB), the degree of damping of the rebound can be adjusted. Turnthe knob clockwise to increase damping, turn it counterclockwise to reduce damping dur-ing rebounding. Make the same damping rate adjustment to both fork legs.

STANDARD ADJUSTMENT– Turn adjusting screw clockwise as far as it will go.– Turn 15 clicks in a counterclockwise direction.

Compression damping of shock absorber (690 Supermoto Prestige)The shock absorber can synchronize the compression damping in the low and high-speedrange separately (Dual Compression Control).Low and high speed refers to the movement of the shock absorber during compression andnot to the speed of the motorcycle.The low and high-speed technology overlaps.The low-speed setting is primarily for slow to normal shock absorber compression rates.The high-speed setting is effective at fast compression rates.Turning in a clockwise direction will increase the damping, turning counterclockwise willdecrease the damping.

STANDARD ADJUSTMENT LOW-SPEED:– Turn adjusting screw [1] clockwise as far as it will go.– Turn 15 clicks in a counterclockwise direction.

STANDARD ADJUSTMENT HIGH-SPEED:– Turn adjusting screw [2] (wrench size 15 mm) clockwise as far as it will go.– Turn 1.5 turns in a counterclockwise direction.

The damping unit of the shock absorber is filled with high-compression nitrogen. Never tryto take the shock absorber apart or to do anymaintenance work yourself. Severe injuries couldbe the result.Never unscrew the screw connection (24mm).


BASIC SETTINGSHOCK ABSORBER WP 4618


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Compression adj. Low Speed (clicks) 20 15 10 10

Compression adj. High Speed (turns) 2 1.5 1 1


Spring preload (mm) 12 12 12 12 12 12 12 12


Adjusting rebound damping of shock absorberBy using the adjusting screw [1], the degree of damping of the rebound can be adjusted.Turn the knob in a clockwise direction to increase damping, turn it in a counterclockwisedirection to reduce damping during rebounding.

STANDARD ADJUSTMENT:– Turn adjusting screw clockwise as far as it will go.– Turn 15 clicks in a counterclockwise direction.

The damping unit of the shock absorber is filled with high-compression nitrogen. Never tryto take the shock absorber apart or to do any maintenance work yourself. Severe injuriescould be the result.

Breathing the fork legs Breath the fork legs regularly (see Maintenance Schedule).To breath, place the motorcycle on the side stand and briefly remove the bleeder screws [2]to allow any overpressure to escape from the fork.

Excessive pressure in the interior of the fork can cause leaks in the fork. If your fork is leak-ing, it is recommended to open the breather plugs before having the seals replaced.



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Compression adj. Low Speed (clicks) 20 15 10 10

Compression adj. High Speed (turns) 2 1.5 1 1




Correcting the chain tension Loosen the collar nut [1], loosen the counternuts [2] and turn the left and right adjustmentscrews [3] the same distance. Tighten the counternuts [2]. To make sure the rear wheel is aligned, the marks on the chain tensioners must be in thesame position on the left and right in relation to the reference marks [B]. Before tighteningthe wheel spindle make sure the chain tensioner [4] rests against the adjustment screwsand the rear wheel is aligned with the front wheel. Tighten the collar nut [1] to 90 Nm.

If you don’t happen to have a torque wrench at hand, make sure you have the tighteningtorque corrected by a KTM dealer as soon as possible. A loose wheel spindle can cause themotorcycle's handling performance to become instable and cause it to crash.

Checking the chain tensionPlace the motorcycle on the side stand. Switch the transmission to neutral and push thechain up. The distance between the chain and swing arm should be 5 mm (0.2 in) at thevertical rib when the upper part of the chain is tensioned (see drawing). Correct the chaintension if necessary.

– If chain tension is too great, parts within the secondary power transmission (chain, chainsprockets, transmission and rear wheel bearings) will be subjected to unnecessary stress,resulting in premature wear and even chain breakage.

– Too much slack in the chain, on the other hand, can result in the chain jumping off thechain wheels. If this happens, the chain could also block the rear wheel or damage theengine.

– In either case the operator is likely to lose control of the motorcycle.

5 m

m5

mm


Checking the chain for wearTo check the chain for wear proceed as follows:Switch the transmission to idle and put a load of approx. 15 kilograms (33 lbs) on the lowerpart of the chain (see illustration). Now measure the distance between 18 chain rollers onthe lower part of the chain. The chain needs to be replaced when the distance is 272 mm(10.70 in). Since chains do not always wear evenly, repeat the measurement at differentparts of the chain.Replace the chain if any X-rings are missing.

NOTE:If you mount a new chain, the sprockets should also be replaced. New chains wear faster ifused on old used sprockets.

Chain maintenanceMaintenance of the X-ring chain is reduced to a minimum. Rinse off any heavy dirt withplenty of water. Residual used grease must be removed prior to lubrication (Motorex ChainClean 611). After drying, use a chain spray specially designed for X-ring chains (MotorexChainlube 622 Strong).

– No lubrication is allowed to reach the rear tire or the brake disk, eitherwise the roadadherence and the rear wheel braking effects would be strongly reduced and the motor-cycle could easily get out of control.

– The chain does not have a chain joint for safety reasons. Always have the chain replacedin an authorized KTM workshop where the service technicans have the required rivetingtool.

– Never mount a normal chain joint.

Also check sprockets and chain guides for wear, and replace if necessary.

15 kg

max. 272 mm

1 2 3 16 17 18


General information on KTM disk brakes BRAKE CALIPERS: The front brake calipers [1] have 4 brake pistons and are radially bolted to the fork legs.The front brake disks are designed as "floating" brake disks, i.e. they are not firmly con-nected to the front wheel.The lateral balance ensures that the brake pads always have the best possible contact to thebrake disk. Apply Loctite 243 to the screws [2] on the brake caliper support and tighten to45 Nm.The rear brake caliper [3] has 1 brake piston and is designed as a "floating brake caliper,i.e. it is not firmly connected to the brake caliper support. The lateral balance ensures thatthe brake pads always have the best possible contact to the brake disk.

For safety reasons, always have maintenance work and repairs to the brake system performedby an authorized KTM workshop.

BRAKE PADS:The brake pads mounted by KTM were tested at length to guarantee maximum braking per-formance and are listed in the homologation papers.

Brake pads available in the accessory trade are often not authorized for operation of yourKTM motorcycle in road traffic. The brake pads design and friction factor and therefore thebraking power can deviate significantly from original KTM brake pads. If you use differentbrake pads than those provided with the original equipment, it cannot be warranted thatthey are authorized for use in road traffic. Your motorcycle will not longer comply with theregulations authorizing the use of vehicles for road traffic and the warranty will be void.


BRAKE FLUID RESERVOIRS:The brake fluid reservoirs on the front and rear wheel brakes have been designed in such away that even if the brake pads are worn it is not necessary to top up the brake fluid. Thereis no reason to remove the reservoir cap under normal conditions. If the brake fluid leveldrops below the minimum either the brake system has a leak or the brake pads are com-pletely worn down. In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:We recommend that you use Motorex DOT 5.1 brake fluid when you refill or change the brakefluid. DOT 5. 1 brake fluid has a wet boiling point of 180°C / 356°F (25°C / 45°F higherthan DOT 4) and is safer for high performance applications. Brake fluid DOT 5.1 is a poly-ethylene glycol based fluid, amber-colored and can be mixed with DOT 4 brake fluid. Donot, in any event, use DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTMmotorcycle gaskets and brake hoses are not designed for DOT 5 brake fluid.Brake fluid is exposed to a high thermal load and absorbs moisture from the air, which low-ers the boiling point. The brake fluid should therefore be changed at the prescribed intervals.

Have the brake fluid for the front and rear brake changed at an authorized KTM workshopevery 2 years.

BRAKE DISCS:Wear will reduce the thickness of the brake disks at the mounting face [4] of the brake pads.At the weakest point [A] the brake disk should not be thinner than indicated on the disk.

Brake disks that are thinner than indicated on the brake disk are a safety risk.


Changing the basic position of the handbrake leverThe adjusting screw [1] allows you to change the basic position of the handbrake lever [2].Press the handbrake lever's outer end forward, and, at the same time, turn the adjustingscrew.

Checking of brake fluid level - front brake (690 Supermoto)The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and thereservoir is provided with an inspection glass. With the reservoir in a horizontal position, thebrake fluid level should not drop below the middle of the glass. The reservoir should be keptcompletely full at all times for best performance.

– If the brake fluid level drops below the minimum either the brake system has a leak orthe brake pads are completely worn down. In this case, consult an authorized KTM dealerimmediately.

– Have the brake fluid changed at an authorized KTM workshop every 2 years.

Checking the front brake fluid level (690 Supermoto Prestige)The brake fluid reservoir for the front brake is located on the right side of the handlebar andhas a "MIN" and a "MAX" mark. The brake fluid level may not fall below the "MIN" markwhen the vehicle is parked in a vertical position.




Checking the front brake padsThe brake pads can be seen from the rear. The linings must be at least 1 mm (0.04 in) thick.

At their most worn point brake pad linings should not be thinner than 1 mm, otherwise theycould lead to brake failure. For your own safety don’t put off having your brake pads changed.

If the brake pads are replaced too late when the lining is partly or completely worn off, thesteel parts on the brake pads will grind against the brake disks. This significantly decreasesthe braking effect and destroys the brake disks.

44

Checking the rear brake padsThe brake pads can be inspected from the rear. The thickness of the linings may not be lessthan 1 mm (0.04 in).

At their most worn point brake pad linings should not be thinner than 1 mm, otherwise theycould lead to brake failure. For your own safety don’t put off having your brake pads changed.

If the brake pads are replaced too late so that the lining is partly or entirely worn away, thesteel components of the brake pad will rub against the brake disc, imparing the brakingeffect and destroying the brake disc.

MAINTENANCE WORK ON CHASSIS AND ENGINE »Checking the rear brake fluid level The brake fluid reservoir for the rear brake is located on the rear right of the vehicle and hasa "MIN" and a "MAX" mark. The brake fluid level may not fall below the "MIN" mark whenthe vehicle is parked in an upright position.



Dismounting and remounting the front wheel Special stands are required to dismount the wheels to make sure the motorcycle is securelyfixed. The front stand only adequately fixes the motorcycle together with the rear stand. Thestands shown in the illustration can be found in the KTM Power Parts catalog.

First mount the rear, then the front stand. Make sure the stands rest on solid ground andare correctly mounted. The front wheel should not touch the ground.


Remove the screws [1] from the brake caliper and carefully pull the brake caliper off thebrake disk towards the rear

Loosen the collar screw [2] and the clamping screws [3] on both fork leg axle passages. Unscrew the collar screw approx 8 turns, press on the collar screw with your hand to pushthe wheel spindle out of the fork leg axle passage and remove the collar screw. Hold thefront wheel while you pull out the wheel spindle. Lift the front wheel off the fork.

– Do not operate the hand brake when the front wheel has been dismounted.– Be careful not to damage the brake disk when you lay the front wheel down.

To mount, lift the front wheel in the fork and mount the wheel spindle and collar screw [2].Tighten the collar screw to 40 Nm. Position the brake calipers and make sure the brake padsare correctly positioned. Apply Loctite 243 to the screw threads [1], mount the distancebushings [4], mount the screws and tighten to 45 Nm.

Take the motorcycle off the front stand, actuate the front wheel brake and vigorously com-press the fork several times to align the fork legs.

Torque the clamping screws [3] on both fork stubs to 15 Nm. Actuate the hand brake untilyou feel the pressure point and check whether the front wheel can easily be turned. Removethe rear stand.

– If you do not have a torque wrench to mount the wheel, have the torques corrected byan authorized KTM workshop as soon as possible. A loose wheel spindle can cause themotorcycle's handling performance to become instable and cause it to crash.

– After mounting the front wheel, keep operating the hand brake until the pressure pointreturns.

– Always keep the brake disks free from oil and grease, otherwise the braking effect willbe significantly reduced.


Dismounting and mounting the rear wheelSpecial stands are required to dismount the wheels to make sure the motorcycle is securelyfixed. The stands shown in the illustration can be found in the KTM Power Parts catalog.

Mount the rear stand. Make sure the stand rests on solid ground and is correctly mounted. The rear wheel should not touch the ground

Unscrew the collar nut [1], remove the chain tensioner [2], hold the rear wheel while youpull out the wheel spindle [3]. Push the rear wheel forward as far as possible and removethe chain from the rear sprocket. Pull back the rear wheel together with the brake calipersupport [4] until the brake caliper support can be tilted to the side. Carefully lift the rearwheel out of the swing arm.

– Do not operate the rear brake when the rear wheel has been dismounted.– Always place the wheel on the ground with the brake disc pointing upwards. Otherwise

the brake disc may be damaged.– If the axle is dismounted, clean the thread of the wheel spindle and collar nut thoroughly

and apply a new coat of grease (Motorex Long Term 2000) to prevent the thread fromjamming.

NOTE: If the rear wheel has been dismounted, you should also check the shock absorption rubber.


Before you mount the rear wheel, clean and grease the bearing face of the bushing [5] andthe shaft seal ring [6]. Clean the dolly at the brake caliper support and swing arm [A].

Assemble in the reverse order. Position the rear wheel in the swing arm and mount the brakecaliper on the brake disk. Allow the brake caliper support and swing arm [A] dollies to engage,place the chain on the gear wheel and mount the wheel spindle. Make sure the chain ten-sioners [2] are mounted in the same way on the left and right. The marks on the chain ten-sioners must be in the same position on the left and right in relation to the reference marks[B]. Before you tighten the collar nut to 90 Nm, press the rear wheel towards the front toallow the chain tensioner to rest against the clamping screws.

– If you don’t happen to have a torque wrench at hand, make sure you have the tighten-ing torque corrected by a KTM dealer as soon as possible. A loose wheel spindle cancause the motorcycle's handling performance to become instable and cause it to crash.

– After mounting the rear wheel, keep operating the footbrake until the pressure point returns.– It is very important to keep the brake disk free from oil and grease, otherwise the brak-

ing effect would be strongly reduced.


Checking the shock absorption rubbers in the rear hubLC4 models have a damped rear wheel hub. For this purpose, the engine power is conveyedfrom the rear sprocket via 6 shock absorption rubbers [1] to the rear wheel. These 6 absorp-tion rubbers wear with increasing operation time, and should be checked for wear wheneverthe rear wheel is dismounted.

For this purpose, lie the rear wheel on a work bench with the rear sprocket upwards, andput the wheel spindle in the hub. Now hold the rear wheel firmly and try to turn the rearsprocket. The rear sprocket may not turn more than maximum 5 mm (0,2 in) measured onthe outside. If the play in the chain wheel is larger, all 6 shock absorption rubbers are to bereplaced.Check the shock absorption rubbers for signs of damage and dirt.

If the shock absorption rubbers are not replaced in good time, the rear sprocket carrier andthe rear hub will be damaged. Allways replace all 6 absorption rubbers, never single rubbers.


Tires, air pressureTire type, tire condition, and how much air pressure the tires have in them affect the wayyour motorcycle rides, and they must therefore be checked whenever you’re getting ready togo anywhere on your motorcycle.

For driving safety and maximum handling, only use tires authorized by KTM (tire releasesare available on the Internet at www.ktm.com) corresponding to the "H" speed index (uo to210 KPH). Other tires can have a negative effect on the motorcycle's handling (e.g. cancause it to "wobble" at higher speeds).

– Tire type and size can be found in the technical specifications and in the homologationcertificate.

– Tire condition has to be checked every time you want to ride your motorcycle. Beforeleaving check for punctures and nails or other sharp objects that might have becomeembedded in the tire.

– Refer to the specific regulations in your country for minimum tire tread requirements.We recommend replacing tires at the latest when the tread is down to 2 mm (0.08 in).

– Tire pressure should be checked regularly on a „cold“ tire. Adapt the air pressure to themotorcycle's total weight. Proper pressure ensures optimum driving comfort and extendsthe life of your tires.

– Do not mount tires which have not been approved by KTM. Other tires could have adverseeffects on the way your motorcycle rides.

– Use tires of the same brand and type for the front and rear wheels.– For your own safety replace damaged tires immediately.– Worn tires can have a negative effect on how your motorcycle performs, especially on wet surfaces.– If air pressure is too low, abnormal wear and overheating of the tire can result– New wheels have a smooth surface, which means that they must be run in to achieve

full grip. For this purpose, ride the motorcycle carefully at moderate speed during thefirst 200 kilometers (125 miles) with new tires, tilting the vehicle at different angles sothat all sections are properly roughened. Tires will not display their full grip character-istics until they are properly run in.

– For reasons of safety, it is recommended to exchange the valve insert whenever a newtire is mounted.


TIRES - AIR PRESSURE

front rear

Road, rider only 2.0 bar28 psi

2.0 bar28 psi

Road, with passenger 2.0 bar28 psi

2.2 bar31 psi

maximum payload 2.0 bar28 psi

2.2 bar31 psi

BatteryThe maintenance-free battery is located under the tank.Maintenance-free means you will not need to check the acid level. Clean the battery termi-nals regularly and grease with acid-free grease if necessary. The charge condition and typeof charge are very important for the battery's service life.

Never operate the motorcycle with a run-down battery or without the battery. This can dam-age the electronic components or safety equipment in either caseand the motorcycle will nolonger be roadworthy.

DISMOUNTING AND MOUNTING THE BATTERY:Remove the seat and the screw [1]. Place a cloth over the subframe and straighten the han-dlebar. Carefully lift the tank and move it towards the rear. Set the tank down on the vehi-cle so that the left spoiler still rests on the compensating tank [2] (see photo). Place a clothbetween the compensating tank and the spoiler to avoid damage. Detach and remove the rubber band [3]. First disconnect the negative terminal, then thepositive terminal from the battery. Take the battery out of the frame towards the right. To mount, position the battery with the terminals facing the front (see photo), connectingthe negative terminal to the battery last. Mount the positive terminal cover and the rubberband. Carefully position the tank, mount the M8 screw and tighten to 15 Nm. Mount theseat.

– If electrolyte (sulphuric acid) leaks from the battery, proceed with great care. The elec-trolyte can cause severe burns.

– In the case of skin contact rinse thoroughly with water.– In the case of contact with the eyes, thoroughly rinse eyes with water for at least 15

minutes. Immediately consult a doctor.– The battery is a closed model but can nevertheless emit explosive gases. Avoid sparks

and open fire near the battery.– Defective batteries must be stored out of the reach of children. Ensure proper disposal

of discarded batteries.


Do not remove the cover [1] otherwise it will be damaged.

STORAGE:If the motorcycle is being immobilized for longer periods of time, remove and charge thebattery. Storage temperature 0 - 35°C (32 - 95°F), avoid direct sunlight.Charge the battery every 3 months.

Charging the battery The battery discharges every day, even if it is not used.Always disconnect the battery when charging. Charge the battery as described in the instructions [2] on the battery housing. Do not exceed the amperage and charging time.Quick charging at a high amperage has an adverse effect on the service life.

To charge the battery while mounted, always use the KTM battery charger (Item no.58429074000) to ensure that the electric system is not damaged by excess voltage. Alwaysremove the battery if using other battery chargers! You can also use this charging device totest the off-load voltage and startability of the battery and generator. It is impossible to over-charge the battery with this device.

Charge the battery immediately if it is empty when you start the motorcycle. If left to standin an uncharged condition for a longer period of time, the battery will run down and sulfa-tize, destroying the battery.


– Do not remove the cover [1] otherwise it will be damaged.– To avoid damage to the on-board electronic system, always disconnect the minus pole before you charge the battery.– To charge, connect the battery to the battery charger before you switch on the battery charger. When the battery is charged, switch off

the battery charger before you disconnect the battery.– Provide adequate ventilation when charging the battery in a closed room; the battery emits explosive gases when charging.– Electrolytes will escape through the safety valves if the battery is charged too long or at an excessive voltage or amperage. This will

reduce battery capacity.– Try to avoid quick charges.

Main fuseThe main fuse protects all power-consuming units on the motorcycle. It is located under thetank on the starter relay.Remove the seat and move the tank back as described in the "Battery" section.After removing the cap [1], the main fuse [2] can be pulled out with long-nose pliers. It hasa capacity of 30 amperes. A spare fuse [3] is located on the starter relay. If a new fuse thathas just been set in gets blown again, you are strongly advised to have it inspected by a KTMdealer. The fuse capacity is 30 Ampere.

– Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be„repaired“. An inexpert treatment could damage the whole electrical installation!

– Contact a specialized KTM dealer, should defects of the electric system occur more frequently.

Mount the tank and seat.Set the clock.

Jump startJump starts are not recommended since they can damage the motorcycle's electronic system.


55MAINTENANCE WORK ON CHASSIS AND ENGINE »Fuses for individual power consumers A fuse box is mounted under the seat containing additional fuses that protect the individ-ual electric power consumers.The fuses are numbered on the inside of the fuse box cover [1]. The following list showswhich fuses correspond to the individual power consumers. Spare fuses [2] with 10 and 15amperes are also found in the fuse box.

NO CONSUMER AMPERES 1 . . . . . . . . . Ignition, instrument cluster, alarm system (optional) . . . . . . . . . . . . . . .102 . . . . . . . . Clock, ignition (CDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 . . . . . . . . . Control motor throttle EPT (Electronic Power Throttle) . . . . . . . . . . . . .104 . . . . . . . . . Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 . . . . . . . . . Horn, brake light, turn signal, alarm system (optional) . . . . . . . . . . . . .107 . . . . . . . . . High beam, low beam, parking light, tail light, license plate lamp . . . . .108 . . . . . . . . . for attachments (switched with the ignition) . . . . . . . . . . . . . . . . . . . .109 . . . . . . . . . for attachments (positive supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1010 . . . . . . . . –SPARE . . . . . Spare fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 15

Replace a blown fuse only with an equivalent one. If a new fuse that has just been set ingets blown again, you are strongly advised to have it inspected by a KTM dealer.

Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be “repaired”.An inexpert treatment could damage the whole electrical installation!

The 8 and 9 fuses [3] are designed for attachments with a maximum power consumption of10 amperes. The respective connector for this equipment is located in the headlight mask.Ask your authorized KTM workshop for details.

PARKING LIGHT BULB:Pull the bulb socket [2] out of the reflector and pull the bulb out of the bulb socket.

HEADLIGHT BULB:Unplug the connector [3] and remove the rubber cap [4]. Turn the bulb socket [5] approx.15° in a counterclockwise direction and remove.Insert a new bulb, making sure the tabs [A] on the lamp engage in the recess [B] in theheadlight. Mount the bulb socket, rubber cap and connector.

Position the headlight mask, mount the screws and tighten to 5 Nm.


Replacing the headlight lamp Remove the 4 screws [1] and carefully remove the headlight mask.

Never touch the glass of the bulb with your fingers. The glass of the bulb must remain absolutelyfree from grease. Heat will otherwise cause the grease to evaporate and settle down on thereflector.

Adjusting the headlight rangeThe payload can make it necessary to correct the headlight range.The headlight range can be adjusted at the back of the headlight with a screwdriver (seephoto). Turning in a clockwise direction will increase the headlight range, turning in a coun-terclockwise direction will reduce the headlight range.

TO CHECK:Determine the distance from the ground to the center of the headlight when your motorcy-cle is loaded and ready for the trip (baggage, driver, passenger). Make a mark on a light wallbehind a level surface at a height corresponding to the center of the headlight. Position yourmotorcycle loaded ready for the trip 5 meters (16,4 ft) away from the wall and switch onthe low beam. The light/dark cut-off line should be 5 cm (2 in) under the mark (see drawing).

Replacing the flasher bulbsRemove the screw on the back of the turn signal, carefully fold the lens [1] towards themotorcycle and remove.Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket.

To mount the lamp reverse the worksteps indicated above.When you mount the screw, firstturn it in a counterclockwise direction until it engages in the thread and then tighten slightly.


5cm

5 m

Cooling systemThe water pump in the engine ensures a forced circulation of the cooling liquid. When theengine is cold, the cooling liquid only circulates in the cylinders and cylinder heads. Thethermostat will open when the engine reaches approx. 70°C (158°F) and the cooling liquidwill also be pumped through the aluminum radiator [1].Cooling is by means of the air stream. The lower the speed, the lower the cooling effect.Soiled cooling fins also impair the cooling effect.If, for example, slow urban traffic or waiting at a traffic light cause little or no air to streamthrough the radiator, the temperature of the cooling liquid will rise. The radiator fan [2] switcheson when the cooling liquid reaches a temperature of 102°C (216°F). Additional air is blownthrough the radiator to prevent the cooling system from overheating.

The temperature indicator [3] will begin to blink and the red cooling liquid temperature warn-ing lamp [4] will light up when the cooling liquid reaches approx. 115°C (239°F), havingexceeded the normal operating temperature. Possible causes:– Slow riding with large loads at a higher air temperature:

If possible increase your running speed, so that more air can blow through the radiators.Should the warning light still be on off after 1500 meters (1 mile), stop immediately,switch off the engine and look for other possible causes.

– The cooling fan on the radiator is not working:The cooling fan must be running, when the cooling liquid temperature is 115°C (239°F)and the ignition is on. If the fan is not working, and there appears to be sufficient cool-ing liquid, the only thing you can do is to drive on to your nearest authorized KTM work-shop at the least possible engine load.

– Too little cooling liquid in the system:Check whether any cooling liquid is leaking out (also on the bottom of the motorcycle).Let the engine cool down and check the cooling liquid level in the radiator (see chapterChecking the cooling liquid level in the radiator). Only continue to drive if there is enoughcooling liquid in the system. Contact an authorized KTM workshop to have the error elim-inated. You will damage the engine if you continue to drive when the cooling liquid tem-perature warning lamp is on.

– Excessive use of the clutch at slow speed.



A mixture of 50% antifreeze and 50% distilled water is used as the cooling liquid. How-ever, the anti-freeze protection must be at least -25° C (-13° F). Aside from antifreezing pro-tection, this mixture also provides great corrosion protection which is why it must not bereplaced by pure water.

– For the cooling system, use only high-grade antifreezer (Motorex Anti-Freeze). Using lowergrade antifreeze agents, can cause corrosion and coolant foaming.

– More antifreeze must be added if you plan to travel to a region where temperatures areexpected to drop below -25°C (-13°F).

Pressure induced by heating of the cooling liquid in the cooling system is controlled by avalve in the radiator cap [5]; a water temperature rising up to 125° C (257° F) is admissi-ble, without fear of problems.Any excess cooling liquid caused by thermal expansion is conducted to the compensatingtank [6]. It will be sucked back in as soon as the temperature in the cooling system drops.

Checking the cooling liquid level in the compensating tankCheck the level of the cooling liquid when the engine is cold. It should fall between the MINand MAX marks on the compensating tank [6].Add cooling liquid (see above for mixture ratio) if the cooling liquid level drops below theMIN mark.If you need to add cooling liquid quite often, the cooling system may leak. If the compen-sating tank is empty, also check the cooling liquid level in the radiator. Have the coolingsystem checked by an authorized KTM workshop.

Coolant drain plug A drain plug [2] to drain the coolant is located on the engine case. Always mount a new gas-ket and tighten the drain plug to 15 Nm.


Checking the cooling liquid level in the radiatorFor better access to the radiator cap [1], move the tank towards the rear, as described inthe "Battery" section.Hold the radiator cap with a cloth, carefully turn in a counterclockwise direction and remove.The radiator should be completely filled with cooling liquid; no air should be in the radiator. If any cooling liquid is missing, the cooling system is probably leaking. Have the coolingsystem checked at an authorized KTM workshop.

If possible, check the cooling liquid level when the engine is cold. If you need to removethe radiator cap when the engine is hot, hold the cap with a cloth and open slowly, allow-ing any excess pressure to escape (danger of scalding).

– If more than 0.5 (0.13 USgal) liter of cooling liquid needs to be added, you will needto bleed the cooling system.

– Only continue to drive if there is enough cooling liquid in the system. Contact an author-ized KTM workshop to have the error eliminated. You will damage the engine if you con-tinue to drive when the cooling liquid temperature warning lamp is on.

Add cooling liquid until it starts to emerge from the vent hole without any air bubbles andimmediately mount the screw to prevent air from getting into the radiator. Fill up the radi-ator with cooling fluid, mount the radiator cap and rest the motorcycle on the side standagain. Move the tank forward, start the engine and allow to warm up until the 5th bar onthe temperature indicator lights up.

Turn off the engine and allow to cool down for about 15 minutes. Move the tank back, slightlytilt the motorcycle to the right, cover the radiator cap with a cloth and carefully remove it.

Cover the cap with a cloth and open slowly to allow excess pressure to escape - can poten-tially cause serious burn injuries.

If necessary, pour cooling liquid into the radiator up to the upper edge of the filler neck,mount the radiator cap and rest the motorcycle on the side stand again. Fill the compen-sating tank with cooling liquid until it reaches a level between the MIN and MAX mark. Closethe compensating tank.Move the tank forward, mount the M8 screw and tighten to 15 Nm. Mount the seat.

61

Bleeding the cooling systemFor better access to the radiator cap, move the tank towards the rear, as described in the"Battery" section.

Remove the radiator cap [1] and bleeder screw [2]. Slightly tilt the motorcycle to the right.

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Changing the original position of the clutch leverThe adjusting screw [1] can be used for individual adjustment of the original position of theclutch lever, thus allowing adjustment to an optimal position for every hand size.Turning the adjusting screw in a clockwise direction will move the clutch lever away fromthe handlebar. Turning the adjusting screw in a counterclockwise direction will move theclutch lever closer to the handlebar.

Adjustment of the clutch lever position is only possible within certain limits. Only turn theadjusting screw manually and never apply excessive force.

Checking the oil level of the hydraulic clutch (690 Supermoto)To check the oil level in the master cylinder of the clutch remove the cover. For this pur-pose, remove screws and cover [2] together with the rubber boot [3]. The oil level in the hor-izontal-standing master cylinder should be 4 mm below the upper edge. If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 75), availablefrom your authorized KTM workshop.

KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch. Do not mixthis oil with any other hydraulic oil. Always use original KTM hydraulic oil (available fromyour authorized KTM workshop) to make sure your clutch operates smoothly. Never refill withbrake fluid.



Adjusting the handlebar tilt Loosen the screws [1]. Adjust the handlebar and tighten the screws to 20 Nm.Make sure the handlebar instruments do not touch the fuel tank when the handlebar is com-pletely turned.

Tilting the handlebar too far back will reduce the steering angle since the handlebar instru-ments will touch the fuel tank

If the handlebar is tilted too far back, the handlebar instruments may damage the fuel tank.

Checking the oil level of the hydraulic clutch (690 Supermoto Prestige)The oil level should be between the „MIN“ and „MAX“ marks with the master cylinder in ahorizontal position.If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 75), availablefrom your authorized KTM workshop.

KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch. Do not mixthis oil with any other hydraulic oil. Always useoriginal KTM hydraulic oil (available fromyour authorized KTM workshop) to make sure your clutch operates smoothly.Never refill with brake fluid.

Engine oilAutomobile engine oil used to be used for four-stroke motorcycles before there were sepa-rate motorcycle specifications. Different technical developments made it necessary to havea separate specification for four-stroke motorcycles - the JASO T903 MA standard. Whereascar engines require long changing intervals, motorcycle engines require a higher power out-put at higher speeds. Most motorcycle engines also use the same oil to lubricate the trans-mission and the clutch. The JASO MA standard responds to these special requirements.

Only use fully synthetic 10W/60 engine oils that meet the JASO MA quality requirements(see information on the can).KTM recommends Motorex Cross Power 4T in the 10W/60 viscosity (for all temperatures).


Checking and adjusting the throttle cable playYou should feel 3-5 mm free travel on the throttle grip when you start to turn it.To adjust, loosen the counternut [1], turn the adjusting screw [2] as required and tightenthe counternut again.Make sure that the throttle grip will return to the idle position automatically once you let goof it.To check the correctness of this setting, start the engine, turn the handlebar left and right,in both cases as far as it will go. This must not cause any changes in idling speed. Otherwise,you have to increase the backlash of the throttle cable.

Refilling engine oil Unscrew the plug [1] and refill engine oil. Wait 30 seconds and check the oil level again.The quantity of oil between the MIN and MAX marks is 0.3 liter (0.08 USgal). Mount theplug and check the engine for leaks.

– Insufficient amounts of or low-grade engine oil lead to premature wear in the engine.– Do not overfill the engine case.– Do not underfill the engine case.


Checking the engine oil level Check the engine oil level when the engine is warm (at least 5 bars on the temperature indi-cator). Place the motorcycle on a level surface (not on the side stand). Wait 30 seconds toallow the oil level to settle in the engine. The oil level should be between the MIN and MAXmarks. Add engine oil if necessary.

Always check the oil level when the engine is warm. A cold engine can distort the measur-ing results. Engine oil expands when heated, increasing the oil level.

Remove the oil filter cover [4] and pull the oil filter out of the engine case with circlip pliers (upside-down).


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

You may only change the engine oil yourself after the warranty period has expired. The war-ranty will become void if you change the oil yourself during the warranty period.

NOTE: Clean the 2 oil screens and replace the 2 oil filters after each oil change.

The engine oil change is to be carried out when the engine is still warm.

An engine having been run warm, and the engine oil in it is very hot – do not burn yourself.

Rest the motorcycle on the side stand on a level surface. Place a pan under the engine tocatch the used oil and remove the oil drain plug [1]. Remove the plug [2] with the oil screen [3].

Remove the oil filter cover [5] and pull the oil filter out of the engine case with circlip pliers (upside-down).

Remove the plug with the oil screen [6].

Thoroughly clean the plugs, cover and both oil screens. Clean all rubber seal rings and checkfor damage; replace if necessary. Clean the sealing areas on the engine case.

Insert the oil screen [6] in the engine case as illustrated, mount the plug and tighten to 15 Nm.Use the same procedure to mount the oil screen on the right side of the engine.


Insert a new oil filter in the engine case, grease the O-rings and mount the oil filter covertogether with the O-ring. Tighten the screws to 6 Nm.

Only use original KTM oil filters. The engine can be damaged if other filters are used.

Mount the oil drain plug with a new seal ring and tighten to 20 Nm.

Unscrew the plug [1]. Add 2 liters (0,53 USgal) of fully-synthetic 10W/60 engine oil accord-ing to JASO MA quality requirement (e.g. Motorex Cross Power 4T 10W/60) and remountthe plug. Start the engine and allow to run warm in neutral until 5 bars on the temperatureindicator light up. Switch off the engine and check the engine oil level (see "Checking theengine oil level").

Check the engine for oil leakage.


TROUBLESHOOTING » 69

If you have your motorcycle serviced as set forth in this manual, no malfunctioning is to be expected. Nevertheless, if an error does arise,we recommend that you look for the error according to the following chart.

Please note that you cannot perform all of the work yourself. If you are not sure, contact your KTM dealer.

TROUBLE CAUSE REMEDY

Engine does not start when thestarter button is actuated

Operating error

Discharged battery

Blown fuse

Main fuse is blown

Defect ignition lock or emergencyOFF switch

Defect safe-starting system.

Turn on the ignition, switch the gear to neutral and switch theemergency OFF switch on, do not accelerate while starting theengine.

Recharge the battery and investigate the causes for discharg-ing; contact an authorized KTM workshop.

Replace fuse 1, 2, 3 or 4 in the fuse box

Remove the seat, move the tank back and replace the main fuse

Check ignition lock and emergency OFF switch, contact anauthorized KTM workshop.

Contact an authorized KTM workshop.

The engine cranks only withpulled clutch lever

A gear is engaged

A gear is engaged and the sidestand is still folded down

Defect safe-starting system.

Shift the transmission to neutral.

Shift the transmission to neutral.


Engine cranks with gearengaged.

Defect safe-starting system. Contact an authorized KTM workshop.



Engine cranks but doesn’t start. Operating error

Blown fuse for the fuel pump

Connector not attached to the fuelline

The plug and socket connector onthe wiring harness is oxidized

Error in the injection system

Pay attention to starting off information(see driving instructions).

Replace fuse 4

Connect the clutch to the fuel line

Remove the panel and fuel tank, clean the plug and socketconnector and spray with contact spray

Visit an authorized KTM workshop

Engine will not reach full power Air filter/fuel filter heavily soiled

Error in the injection system

Have the air filter/fuel filter replaced at an authorized KTMworkshop

Visit an authorized KTM workshop

Engine overheats Insufficient cooling liquid

Radiator fins are extremely dirty

Foam forms in cooling system

Radiator hose is kinked or damaged

Thermostat defective

Blown fan fuse

Refill cooling liquid (see maintenace work), check cooling sys-tem for leaks

Clean radiator with water jet

Replace cooling liquid, use antifreezer with brand name

Run the radiator hose correctly or replace

Have the thermostat checked (opening temperature 70°C,(158°F) or replaced; contact an authorized KTM workshop

Replace fuse 5



Engine overheats Defect fan or thermoswitch for fan

Air in the cooling system


Bleed the cooling system (see Maintenance work)

FI lamp is blinking / lights up Error in the injection system Visit an authorized KTM workshop

Engine stalls while driving No fuel

The fuse for the ignition or fuel pumpis blown

Refuel

Replace fuse 1, 2 or 4

High oil consumption Engine oil level too high

Engine oil too thin (viscosity)

Kink in engine vent hose

Check engine oil level when the engine is warm; correct ifnecessary

Use thicker engine oil; see chapter „Engine oil“

Remove the seat, move the tank back and check engine venthoses

Headlight and position light fail Blown fuse Replace fuse 7

Turn signal, brake light and horndo not function

Sicherung durchgeschmolzen Replace fuse 6

Time is not displayed or not cor-rectly displayed

Blown fuse, thus no continuouspower supply

Replace fuse 2 and set the clock.



The battery is discharged The ignition (power consumer) has-n’t been switched off

The battery isn’t charged by thegenerator

Recharge the battery according to the relevant instructions.

Voltage regulator and generator should be checked by anauthorized KTM workshop.

No values are visible in the com-bined instrument display.

Blown fuse Replace fuse 1

The speed indication on thecombined instrument is notworking

Pickup cable is damaged or con-tacts on the cable connector haveoxidized

Check the pickup cable for damage, visit an authorized KTMworkshop

The blink code indicates which component is affected by an error. This allows the error to be identified if no diagnosis tool is available.

BLINK CODE SIGNAL / COMPONENT ERROR DESCRIPTION ENGINE

02 Pulse generator Malfunction Stalls

06 Throttle sensor Output signal too low /high Continues to run

08 APS sensor (throttle grip sensor) Output signal too low /high Continues to run

09 Intake manifold air pressure Output signal too low /high Continues to run

12 Coolant temperature sensor Output signal too low /high Continues to run


BLINK CODE SIGNAL / COMPONENT ERROR DESCRIPTION ENGINE

13 Air temperature sensor Output signal too low /high Continues to run

14 Ambient air pressure sensor Output signal too low /high Continues to run

15 Tilt angle sensor Output signal too low /high Continues to run

17 Lambda probe Malfunction Continues to run

24 Control unit voltage supply Malfunction Continues to run

25 Side stand switch Short circuit to ground Continues to run

26 EPT electric motor Hall sensor Output signal too low /high Continues to run

27 EPT battery voltage control unit Output signal too low /high Continues to run

33 Injection nozzle Malfunction Stalls

37 Ignition coil Malfunction Stalls

41 Fuel pump relay Short circuit to ground / positive Stalls

45 Lambda probe heater Short circuit to ground / positive Continues to run

53 Purge valve for carbon canister Short circuit to ground / positive Continues to run

54 Secondary air valve Short circuit to ground / positive or interruption Continues to run

55 EPT electric motor control unit Supply voltage too low/high Continues to run

58 EPT voltage control unit Malfunction Continues to run

60 EPT electric motor Output signal too low /high Continues to run

68 Manifold air pressure (MAP) sensor leak O-Ring or sensor damaged Continues to run

90 EPT throttle valve position Abnormal deviation between setpoint andactual value

Continues to run

91 CAN Communication Malfunction Continues to run

92 EPT control unit battery voltage electric motor Output signal too low /high Continues to run

CLEANING » 74

Regular cleaning and paintwork care are part of the maintenance work and help to maintain the value of your motorcycle.

Never clean the motorcycle with a power washer or a strong water jet, otherwise the pressure will allow water to enter the electric compo-nents, plugs, cables, bearings, etc. which can cause malfunctioning or can lead to premature wear of these components.

– Before you wash your motorcycle, close the muffler openings.– Use warm water with a commercial detergent and sponge. Coarse dirt can be removed with a soft water jet. Areas that are heavily soiled

can be sprayed with a motorcycle cleaner (e.g. Motorex Motoclean 900) and cleaned with a brush.– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until

the engine has reached the working temperature and also use the brakes. Due to the heat, the water also evaporates at the unapproach-able parts of the engine and the brakes.

– After the motorcycle has cooled down, oil or lubricate all of the friction bearings and bearing positions and treat the chain with chainspray. Treat all bare areas (except brake disks) with a corrosion inhibitor (e.g. Motorex Protect & Shine).

– The exhaust pipes and mufflers are made of stainless steel and should be treated with a suitable care product.– To prevent failures in the electric system, you should treat the ignition lock, the emergency OFF switch, light switch and the socket con-

nectors with contact spray.– Treat all of the painted parts with a mild paint care product (e.g. Motorex Moto Polish).

CONSERVATION FOR WINTER OPERATION »In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions against the aggressive road salt.– clean motorcycle thoroughly and let it dry– treat engine, swing arm, and all other bare parts (except for brake discs) with a wax-based anti-corrosion agent.

Keep anti-corrosion agent from getting into contact with the brake discs, for otherwise this will significantly reduce the braking power.

After rides on salted roads, clean motorcycle thoroughly with cold water and let it dry well!

STORAGE » 75

Should you desire to make a pause over a longer space of time, please observe the following instructions:– Drive the tank empty to be able to fill up with fresh fuel when starting the motorcycle up again.– Clean motorcycle thoroughly (see chapter: CLEANING)– Change engine oil and oil filter (old engine oil contains aggressive contaminations).– Check antifreezer and amount of cooling liquid.– Correct tire pressure.– Disassemble and charge battery (see chapter: BATTERY).– Jack up the motorcycle if possible so the wheels do not touch the ground.– The storage place should be dry and not subject to excessive temperature fluctuations.– Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use non air permeable materials as a possible humidity might

not be able to escape and could cause corrosion.

It would be very bad to let the engine run for a short time during the storage period. The engine would not get warmed up enough and thethus developed steam would condense during the combustion process and cause the valves and exhaust to rust.

RE-INITIATION AFTER TIME OF STORAGE– Mount the charged battery (pay attention to polarity) and set the clock.– Fill up tank with fresh fuel.– Check motorcycle as before each start (see driving instructions).– Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any service jobs,repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload a mechanics’ shops). Thisway, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.

TECHNICAL SPECIFICATIONS – CHASSIS » 76

CHASSIS 690 SUPERMOTO 2007 690 SUPERMOTO PRESTIGE 2007

Frame Chromoly trellis frame, powder-coated

Fork WP Suspension – Up Side Down 4860 ROMA

Spring travel front 210 mm (8.27 in)

Rear suspension WP Suspension - 4618 shock absorber - PRO-LEVER relay lever

Spring travel rear 210 mm (8.27 in)

Front brake 4-piston fixed radial caliper, brake disc Ø 320 mm (12.6 in)

Rear brake single-piston floating caliper, brake disc Ø 240 mm (9.45 in)

Authorized front tires * BRIDGESTONE Battlax BT090F METZELER Sportec M3 Front

120/70 R17 M/C 58H 120/70 ZR17 M/C 58W

Air pressure Road, driver only................................................2.0 bar (28 psi)Road, with passenger / maximum payload ............2.0 bar (28 psi)

Authorized rear tires * BRIDGESTONE Battlax BT090R PRO METZELER Sportec M3

160/60 R17 M/C 69H 160/60 ZR17 M/C 69W

Air pressure Road, driver only................................................2.0 bar (28 psi)Road, with passenger / maximum payload ............2.2 bar (31 psi)

Fuel tank capacity 13 liters (3.44 USgal), 2.5 liters (0.66 USgal) Reserve

Lighting high beam + low beam ..................................H4 12V 60/55W (socket P43t)position light front.............................................12V 5W (socket W2.1x9.5d)Instrument lights + indicator lamp..........................................................LEDposition light rear ..................................................................................LEDstoplight ..............................................................................................LEDlicens plate illumination ....................................12V 5W (socket W2.1x9.5d)flashers ................................................................12V 10W (socket BA15s)

* further tire releases are available on the Internet at www.ktm.com


CHASSIS 690 SUPERMOTO 2007 690 SUPERMOTO PRESTIGE 2007

Battery maintenance-free battery 12V / 8.6 Ah

Gear ratio – rear wheel 17:41 (17:42)

Chain 5/8 x 1/4” X-ring

Steering head angle 63.5°

Wheel base 1472 ± 15 mm (57.95 ± 0.6 in)

Seat height, unloaded 880 mm (34.65 in)

Ground clearance, unloaded 245 mm (9.65 in)

Dry weight 154 kg (339.5 lbs)

Max. axle load front 150 kg (330.7 lbs)

Max. axle load rear 200 kg (440.9 lbs)

Max. total load 350 kg (771.6 lbs)

FORK 690 SUPERMOTO 690 SUPERMOTO PRESTIGE

Type 14.18.7C.07 WP Suspension 14.18.7C.08 WP Suspension

Spring 5.2 - 430 5.2 - 430

Air chamber length 100 mm (39.37 in) 100 mm (39.37 in)

Fork oil SAE 2.5 SAE 2.5

SHOCK ABSORBER 690 SUPERMOTO 690 SUPERMOTO PRESTIGE

Type 15.18.9C.07 WP Suspension 15.18.7C.08 WP Suspension

Spring 65 - 230 65 - 230

Spring preload 12 mm (0.472 in) 12 mm(0.472 in)


BASIC SETTINGFORK WP 4860 ROMA

SUPERMOTO SUPERMOTO PRESTIGE

Dri

ving

Com

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Bas

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Dri

ving

Spo

rt

Max

imum

Pay

load

Dri

ving

Com

fort

Bas

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ng

Dri

ving

Spo

rt

Max

imum

Pay

load

Compression adjuster (clicks) - - - - 20 15 10 10



SUPERMOTO SUPERMOTO PRESTIGE

Dri

ving

Com

fort

Bas

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ng

Dri

ving

Spo

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Max

imum

Pay

load

Dri

ving

Com

fort

Bas

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ng

Dri

ving

Spo

rt

Max

imum

Pay

load

Compression adjuster Low Speed (clicks) - - - - 20 15 10 10

Compression adjuster High Speed (turns) - - - - 2 1,5 1 1




TIGHTENING TORQUES – CHASSIS 690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007

Screw for side stand switch M4 Loctite 243 + 2 Nm

Spoke nipple M4.5/M5 5 Nm

Screw for fuel pump, pressure regulator M5 4 Nm

Screw for fuel level sensor M5 3 Nm

Screw for foot brake pedal surface M5 Loctite 243 + 6 Nm

Screw for plastic clamp brake line fork leg M5 2 Nm

Screw for heat protector on exhaust M5 Loctite 243 + 5 Nm

Screw for side cover M5 2 Nm

Screw for seat lock M5 Loctite 222 + 3 Nm

Screw for starter cable - starter M5 3 Nm

Pushrod ball joint foot brake cylinder M6 Loctite 243 + 10 Nm

Remaining screws for tank M6 6 Nm

Screw for compensating tank rear wheel brake M6 5 Nm

Screw for battery rack, control unit holder M6 3 Nm

Screw for fuel cock M6 6 Nm

Screw for front/rear brake disk M6 Loctite 243 + 14 Nm

Screw for foot brake cylinder M6 Loctite 243 + 10 Nm

Screw for horn M6 Loctite 243 + 6 Nm

Screw for license plate holder M6 8 Nm

Screw for lower radiator mount M6 5 Nm

Screw for magnetic side stand holder M6 Loctite 243 + 10 Nm

Screw for rectifier regulator M6 8 Nm

Screw for headlight mask M6 5 Nm

Screw for side stand bracket M6 Loctite 243 + 10 Nm



Screw for SAS valve M6 6 Nm

Nut for rear sprocket screw M8 Loctite 243 + 35 Nm

Nuts for header - cylinder head M8 copper paste + 25 Nm

evenly, do not bend washer

Screw for silencer exhaust clamp M8 25 Nm

Screw for header exhaust clamp M8 copper paste + 25 Nm

Screw for side stand spring bracket M8 Loctite 243 + 25 Nm

Screw for rear footrest support M8 25 Nm

Screw for rear footrest bracket M8 Loctite 243 + 25 Nm

Screw for upper triple clamp M8 12 Nm

Screw for lower triple clamp M8 15 Nm

Screw for fork stub M8 15 Nm

Screw for grip M8 6 Nm

Screw for steering stem clamping M8 20 Nm

Screw for header - silencer M8 copper paste + 25 Nm

Screw for handlebar clamp M8 20 Nm

Screw for upper subframe M8 Loctite 243 + 35 Nm

Screw for side stand bracket M8 Loctite 243 + 25 Nm

Screw for tank bearing M8 15 Nm

Screw for linkage bracket, front engine holder M8 Loctite 243 + 25 Nm

Screw for front/rear brake disk M8x1.25 Loctite 243 + 30 Nm

Engine mount screws M10 Loctite 243 + 45 Nm

Screw for upper/lower shock absorber M10 Loctite 243 + 45 Nm

Screw for handlebar mount M10 20 Nm



Screw for side stand M10 Loctite 243 + 35 Nm

Screw for front brake caliper M10x1.25 Loctite 243 + 45 Nm

Screw for lower subframe M10x1.25 Loctite 243 + 45 Nm

Lambda probe M12x1.25 24.5 Nm

Nut for frame - connecting lever - rocker arm - swinging fork M14x1.5 100 Nm

Nut for swing arm pivot M16x1.5 100 Nm

Nut for engine sprocket M20x1.5 Loctite 243 + 80 Nm

Screw for steering head M20x1.5 12 Nm

Adjusting ring for swing arm support M24x1.5 25 Nm

Screw for front wheel spindle M24x1.5 40 Nm

Nut for rear wheel spindle M25x1.5 90 Nm

Remaining chassis screws M5M6M8M10

4 Nm10 Nm25 Nm45 Nm

Remaining chassis screws M6M8M10

15 Nm30 Nm50 Nm

TECHNICAL SPECIFICATIONS – ENGINE » 82

ENGINE 690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007

Design Single-cylinder, 4-stroke Otto engine with balancer shaft

Displacement 654 cc

Bore / Stroke 102 / 80 mm (4.02 / 3.15 in)

Compression ratio 11.8 : 1

Fuel unleaded fuel with at least RON 95 (USA: Premium PON 91)

Valve timing 4 valves OHC, roller rocker arms

Valve diameter Intake: 40 mm (1.57 in) Exhaust: 34 mm (1.34 in)

Valve clearance, cold 0.07 - 0.13 mm (0.00276 - 0.00512 in)

Crankcase bearing Two-cylinder roller bearing

Conrod bearing Needle bearing

Piston pin bearing Bronze bushing

Piston Light alloy – forged

Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring

Engine lubrication Semi-dry sump with 2 Eaton pumps

Engine oil Fully-synthetic 10W/60 engine oil according to the JASO T903 MA specification (Motorex Cross Power 4T 10W/60)

Quantity of engine oil approx. 2 liters (0.53 USgal)

Primary drive Straight-toothed spur wheels 36 : 79

Clutch APTC multi-disc wet clutch, hydraulically operated

Transmission 6-speed claw shiftedGear ratio 1st gear 14 : 35

2nd gear 16 : 283rd gear 21 : 284th gear 21 : 235th gear 23 : 226th gear 23 : 20

TECHNICAL SPECIFICATIONS – ENGINE » 83

ENGINE 690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007

Mixture preparation electronically controlled gasoline injection

Ignition system breakerless transistorized electronic ignition system with digital ignition advance

Alternator 12V 224W at 5000 rpm

Spark plug NGK LKAR8AI-9

Electrode distance 0.9 mm (0.035 in)

Cooling system liquid cooled

Cooling liquid 1.2 liter (0.317 USgal), 50% antifreeze, 50% distilled water, at least –25°C (-13°F)

Starting aid electric starter

HEAD WORD INDEX » 84

Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Adjusting compression damping of fork (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . . . .35Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . . . .35Adjusting rebound damping of shock absorber . . . . . . . . . . . .37Adjusting the fork and shock absorber . . . . . . . . . . . . . . . . .35Adjusting the handlebar tilt . . . . . . . . . . . . . . . . . . . . . . . . .63Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . . . .57Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . . . .61Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Changing the basic position of the handbrake lever . . . . . . . . .42Changing the engine oil and the oil filter, cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Changing the original position of the clutch lever . . . . . . . . . .62Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Chassis number, type label . . . . . . . . . . . . . . . . . . . . . . . . . . .6Check the following before each start . . . . . . . . . . . . . . . . . .22Checking and adjusting the throttle cable play . . . . . . . . . . . .64Checking of brake fluid level - front brake (690 Supermoto) . .42Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . . . .39Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .38Checking the cooling liquid level in the compensating tank . . .59Checking the cooling liquid level in the radiator . . . . . . . . . . .60Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . .65Checking the front brake fluid level (690 Supermoto Prestige) .42Checking the front brake pads . . . . . . . . . . . . . . . . . . . . . . . .43

Checking the oil level of the hydraulic clutch (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . . . .63Checking the oil level of the hydraulic clutch (690 Supermoto) 62Checking the rear brake fluid level . . . . . . . . . . . . . . . . . . . .44Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . . . .44Checking the shock absorption rubbers in the rear hub . . . . . .50CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Clutch lever (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . .7Clutch lever (690 Supermoto) . . . . . . . . . . . . . . . . . . . . . . . . .7Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Combined instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Combined instrument display . . . . . . . . . . . . . . . . . . . . . . . . .8Compression damping of fork (690 Supermoto Prestige) . . . . .18Compression damping of shock absorber (690 Supermoto Prestige) . . . . . . . . . . . . . . . . . . . . . . . . . .36CONSUMER INFORMATION FOR USA ONLY . . . . . . . . . . . . .86CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .74Coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Cooling liquid temperature display . . . . . . . . . . . . . . . . . . . .11Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58Correcting the chain tension . . . . . . . . . . . . . . . . . . . . . . . .38Damping action during compression of shock absorber (690 Supermoto Prest) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Dismounting and mounting the rear wheel . . . . . . . . . . . . . . .48Dismounting and remounting the front wheel . . . . . . . . . . . .46DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .22Emergency OFF tip switch, starter tip switch . . . . . . . . . . . . .14Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . . . .6Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

HEAD WORD INDEX » 85

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Fuel, refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Function buttons on combined instrument . . . . . . . . . . . . . . .8Fuses for individual power consumers . . . . . . . . . . . . . . . . . .55General information on KTM disk brakes . . . . . . . . . . . . . . . .40GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .2INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Instructions for initial operation . . . . . . . . . . . . . . . . . . . . . .20INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .34OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . .7Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .30Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . . . .18Rebound damping of shock absorber . . . . . . . . . . . . . . . . . . .19Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . . . .57Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . . . .56Running in the LC4 engine . . . . . . . . . . . . . . . . . . . . . . . . . .20Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . . . . .15

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .6Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .76TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .82Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

CONSUMER INFORMATION FOR USA ONLY » 86

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Sticker positions: 54

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67 8 21


750.01.099.000 FORK SHOCK

SETTING

Com

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(cl

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)

Reb

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(cl

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Com

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Low

Spe

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Com

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Hig

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ns)

Reb

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(cl

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Spr

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oad

(mm

)

Comfort - 20 - - 20 12

BASIC SETTING - 15 - - 15 12Sport - 10 - - 10 12

Max. payload - 10 - - 10 12

[8] Suspension setting[7] Before you go for the first ride

[5] Vehicle emission

[2] Type label CAN

[6] Noise emission

[1] EAVP5

mm

5m

m

750.04.099.000

[4] Chain tension

[3] Type label USA


REPORTING SAFETY DEFECTSIf you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic SafetyAdministration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remady cam-paign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–800–424–9393 or visit the website www.nhtsa.dot.gov , or write to: NHTSA, U.S. Department ofTransportation, 400 7th Street, Southwest, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.

NOISE EMISSION WARRANTYKTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first per-son who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to: KTM North America, Inc. 1119 Milan Avenue, Amherst, Ohio 44001, Telephone: (440) 9853553

TAMPERING WARNINGTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED. FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF:1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into

any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or2) The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.1) Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.2) Removal or puncturing of any part of the intake system.3) Lack of proper maintenance.4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

WARNING STATEMENTThis product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penal-ties under state and local ordinances.

CONSUMER RIGHTSLimited Warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact KTM North America, Inc., Customer Relations, 1119 MilanAvenue, Amherst, Ohio 44001. Your rights may vary, please refer to the applicable state laws.

690 LC4 SUPERMOTO

KTM Sportmotorcycle AG A–5230 Mattighofenwww.ktm.at

01/2007 FOTO: MITTERBAUERKTM Group Partner

ART. NR. 3.211.147 DE

BEDIENUNGSANLEITUNG 2007

OWNER'S MANUAL 2007 - Enduro Team

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Transcript of OWNER'S MANUAL 2007 - Enduro Team