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Ktm 690 supermoto SM Repair manual

This repair manual provides instructions for repairing and maintaining 2008 KTM 690 Supermoto motorcycles. It covers topics such as adjusting and servicing the fork, shock absorber, exhaust, fuel tank, wheels, brakes, lights, engine, clutch, cooling system, and other systems. The document provides detailed procedures for tasks like removing and installing components, checking wear limits, bleeding fluids, and diagnosing electrical issues. Safety practices and only using original KTM parts are emphasized.

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REPAIR MANUAL 2008 690 SUPERMOTO R EU 690 Supermoto R AUS/UK 690 Supermoto R USA 690 SUPERMOTO EU 690 SUPERMOTO AUS/UK Article no. 3206055en
INTRODUCTION 1 INTRODUCTION Read this repair manual carefully and thoroughly before beginning work. Only use ORGINAL KTM SPARE PARTS. The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this manual. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic. All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica- tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria
CONTENTS 2 CONTENTS MEANS OF REPRESENTATION ............................................ 5 IMPORTANT NOTES............................................................ 6 LOCATION OF SERIAL NUMBERS ........................................ 7 Chassis number/type label (690 SUPERMOTO R EU/AUS/UK, 690 Supermoto).............................................................. 7 Chassis number/type label (690 Supermoto R USA)............ 7 Key number .................................................................... 7 Engine number................................................................ 7 Fork part number............................................................. 8 Shock absorber part number............................................. 8 MOTORCYCLE..................................................................... 9 Jacking up rear of motorcycle ........................................... 9 Jacking up the middle of the motorcycle............................ 9 Jacking up front of motorcycle .......................................... 9 Take the rear from the work stand. .................................. 10 Removing the motorcycle from the work stand.................. 10 Taking front from work stand .......................................... 10 Starting ........................................................................ 10 01/FORK, TRIPLE CLAMP.................................................. 12 Adjusting compression damping of fork (690 Supermoto R) ....................................................... 12 Adjusting rebound damping of fork.................................. 12 Bleeding fork legs.......................................................... 12 Removing fork legs ........................................................ 13 Installing fork legs......................................................... 14 Dismantling fork legs (690 Supermoto) ........................... 16 Assembling fork legs (690 Supermoto) ............................ 19 Dismantling fork legs (690 Supermoto R) ........................ 23 Assembling fork legs (690 Supermoto R)......................... 26 Checking fork................................................................ 30 04/SHOCK ABSORBER, SWINGARM................................... 32 Adjusting high-speed compression damping of the shock absorber (690 Supermoto R) .......................................... 32 Adjusting the low-speed compression damping of the shock absorber (690 Supermoto R) ................................. 32 Adjusting rebound damping of the shock absorber ............ 33 Removing the shock absorber ......................................... 33 Installing shock absorber................................................ 34 Removing spring (690 Supermoto).................................. 35 Installing shock absorber (690 Supermoto)...................... 36 Dismantling shock absorber (690 Supermoto) .................. 37 Assembling shock absorber (690 Supermoto)................... 37 Filling shock absorber with nitrogen (690 Supermoto)....... 39 Disassembling piston rod (690 Supermoto)...................... 40 Assembling piston rod (690 Supermoto).......................... 41 Removing spring (690 Supermoto R)............................... 42 Installing spring (690 Supermoto R) ............................... 43 Dismantling shock absorber (690 Supermoto R)............... 44 Assembling shock absorber (690 Supermoto R)................ 45 Bleeding and filling shock absorber (690 Supermoto R) .... 47 Filling shock absorber with nitrogen (690 Supermoto R) ... 49 Disassembling piston rod (690 Supermoto R)................... 50 Assembling piston rod (690 Supermoto R)....................... 51 Removing heim joint...................................................... 52 Installing heim joint....................................................... 52 Checking shock absorber................................................ 53 05/EXHAUST .................................................................... 55 Removing exhaust manifold............................................ 55 Installing exhaust manifold............................................. 56 07/FUEL TANK, SEAT, TRIM.............................................. 58 Opening filler cap.......................................................... 58 Closing filler cap ........................................................... 58 Removing the seat......................................................... 58 Mounting the seat ......................................................... 58 Dismounting the fuel tank .............................................. 58 Installing the fuel tank................................................... 59 Reinstalling the fuel tank ............................................... 60 Positioning the fuel tank ................................................ 61 09/FRONT WHEEL ............................................................ 62 Removing front wheel .................................................... 62 Fitting front wheel ......................................................... 62 Checking tire air pressure............................................... 63 Tire condition checking.................................................. 63 Checking brake discs ..................................................... 64 10/REAR WHEEL .............................................................. 65 Removing rear wheel...................................................... 65 Fitting rear wheel .......................................................... 65 Checking the chain tension ............................................ 66 Adjusting chain tension.................................................. 66 Checking chain wear...................................................... 67 Checking rear sprocket / engine sprocket for wear............. 68 Cleaning the chain......................................................... 68 Checking the rear hub rubber dampers ............................ 68 Checking spoke tension (690 Supermoto)........................ 69 11/WIRING HARNESS, BATTERY ....................................... 70 Removing the battery..................................................... 70 Installing the battery...................................................... 70 Disconnecting negative (minus) cable of battery ............... 70 Reconnecting negative (minus) cable of battery................ 71 Recharging the battery................................................... 71 Changing the main fuse ................................................. 72 Changing fuses of individual power consumers ................. 73 13/BRAKE SYSTEM........................................................... 74 Checking the front brake linings...................................... 74 Adjusting basic position of handbrake lever...................... 74 Checking front brake fluid level....................................... 74 Adding brake fluid for front brake.................................... 75 Checking the rear brake linings....................................... 76 Checking free play of foot brake lever .............................. 76 Checking rear brake fluid level........................................ 77 Topping up brake fluid of rear brake................................ 77 14/LIGHT SYSTEM, INSTRUMENTS ................................... 78 Setting kilometers or miles ............................................. 78 Setting the clock ........................................................... 78 Combination instrument - setting/resetting TRIP 1 display ......................................................................... 78 Combination instrument - setting/resetting TRIP 2 display ......................................................................... 79 Checking headlamp setting............................................. 79 Adjusting the headlight range ......................................... 79 Removing headlight mask with headlight ......................... 79 Refitting the headlight mask with the headlight................ 80 Changing the parking lamp............................................. 80 Changing headlight bulb ................................................ 81 Changing flasher bulb .................................................... 81 30/ENGINE....................................................................... 82 Removing the engine ..................................................... 82 Installing the engine ...................................................... 85 30/DISASSEMBLING THE ENGINE..................................... 90 Clamping engine into engine work stand .......................... 90 Draining engine oil ........................................................ 90 Removing starter motor .................................................. 90 Removing valve cover..................................................... 90
CONTENTS 3 Removing generator cover............................................... 91 Removing spacing sleeve................................................ 91 Removing gear position sensor........................................ 91 Removing oil filter ......................................................... 91 Removing thermostat ..................................................... 92 Setting engine to ignition top dead center........................ 92 Removing water pump wheel .......................................... 92 Removing clutch cover................................................... 93 Removing spacer and spring ........................................... 93 Removing spark plug ..................................................... 93 Removing timing chain tensioner .................................... 94 Removing camshafts...................................................... 94 Removing cylinder head ................................................. 94 Removing piston............................................................ 94 Removing rotor.............................................................. 95 Removing timing chain rails ........................................... 95 Removing timing chain and timing chain sprocket ............ 96 Removing ignition pulse generator................................... 96 Removing clutch cage.................................................... 96 Removing primary gear................................................... 98 Removing starter drive ................................................... 98 Removing shift shaft...................................................... 98 Removing shift drum locating ......................................... 98 Removing locking lever .................................................. 99 Removing oil pumps ...................................................... 99 Removing left engine case.............................................. 99 Removing crankshaft and balancer shaft........................ 100 Removing transmission shafts....................................... 100 30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 102 Work on the right section of the engine case .................. 102 Work on the left section of the engine case .................... 103 Work on the clutch cover.............................................. 104 Removing crankshaft bearing inner ring ......................... 105 Removing balancer shaft drive wheel............................. 105 Changing the conrod bearing ........................................ 105 Checking crankshaft run-out at bearing pin .................... 107 Installing balancer shaft drive wheel.............................. 107 Installing crankshaft bearing inner ring.......................... 107 Measuring axial clearance of crankshaft and balancer shaft .......................................................................... 108 Cylinder - Nikasil® coating............................................ 108 Checking/measuring cylinder ........................................ 109 Checking/measuring piston........................................... 109 Checking piston ring end gap........................................ 110 Checking piston/cylinder mounting clearance ................. 110 Checking oil pumps for wear......................................... 111 Replacing autodecompressor ........................................ 111 Preparing timing chain tensioner for installation............. 112 Checking timing assembly ............................................ 112 Removing rocker arm ................................................... 113 Changing camshaft bearing .......................................... 113 Removing valves.......................................................... 114 Checking valves........................................................... 114 Checking valve springs................................................. 115 Checking valve spring retainer ...................................... 115 Checking cylinder head ................................................ 115 Installing valves .......................................................... 116 Installing rocker arm.................................................... 117 Dismantling antihopping clutch .................................... 117 Checking clutch .......................................................... 118 Preassembling antihopping clutch................................. 119 Checking shift mechanism ........................................... 120 Preassembling shift shaft ............................................. 120 Dismantling main shaft ................................................ 121 Dismantling countershaft ............................................. 121 Checking transmission ................................................. 122 Assembling main shaft................................................. 123 Assembling countershaft .............................................. 124 Checking electric starter drive....................................... 125 Removing freewheel..................................................... 125 Checking freewheel...................................................... 126 Installing freewheel ..................................................... 126 30/ASSEMBLING THE ENGINE........................................ 128 Installing transmission shafts ....................................... 128 Installing crankshaft and balancer shaft......................... 129 Installing left engine case ............................................ 129 Installing oil pumps..................................................... 130 Installing locking lever ................................................. 130 Installing shift drum locating........................................ 130 Installing shift shaft..................................................... 131 Installing starter drive .................................................. 131 Installing primary gear ................................................. 131 Installing clutch cage................................................... 132 Installing ignition pulse generator ................................. 133 Installing timing chain and timing chain sprocket........... 133 Installing timing chain rails .......................................... 134 Installing rotor............................................................. 134 Adjusting ignition pulse generator distance .................... 134 Setting engine to top dead center.................................. 135 Installing piston .......................................................... 135 Installing cylinder head................................................ 136 Installing camshafts .................................................... 137 Installing timing chain tensioner................................... 138 Checking valve clearance ............................................. 138 Adjusting valve clearance ............................................. 138 Installing spark plug .................................................... 139 Installing spacer and spring.......................................... 139 Installing clutch cover.................................................. 140 Mounting water pump cover.......................................... 140 Installing thermostat.................................................... 140 Installing oil filter........................................................ 141 Installing gear position sensor....................................... 141 Installing spacing sleeve .............................................. 141 Installing oil screens.................................................... 142 Installing generator cover ............................................. 142 Installing starter motor................................................. 143 Installing valve cover ................................................... 143 Taking engine off universal mounting rack ..................... 143 32/CLUTCH .................................................................... 144 Checking/correcting fluid level of hydraulic clutch .......... 144 35/WATER PUMP, COOLING SYSTEM .............................. 145 Draining coolant.......................................................... 145 Filling/aerating cooling system...................................... 145 Checking antifreeze and coolant level............................ 146 Checking the coolant level............................................ 147 38/LUBRICATION SYSTEM .............................................. 149 Oil circuit ................................................................... 149 Checking engine oil level.............................................. 149 Changing engine oil and oil filter, cleaning oil screens .... 150 Draining engine oil ...................................................... 150 Removing the oil filter.................................................. 151 Mounting oil filter........................................................ 151 Cleaning oil screens..................................................... 151
CONTENTS 4 Filling up with engine oil.............................................. 152 Topping up engine oil .................................................. 153 41/THROTTLE VALVE BODY............................................. 154 Throttle position sensor - checking position.................... 154 Throttle position sensor - adjusting position ................... 155 Actuator diagnostics - throttle stepper motor .................. 155 Checking emergency running position of the throttle valve .......................................................................... 156 Adjusting throttle valve emergency running position........ 156 Throttle grip sensor - checking position.......................... 157 Throttle grip sensor - adjusting position ......................... 157 Removing EPT control unit holder ................................. 158 Installing EPT control unit holder.................................. 158 Removing rollover sensor.............................................. 159 Installing rollover sensor............................................... 159 ENGINE CONTROL ERROR CODE..................................... 160 ENGINE CONTROL ERROR CODE..................................... 164 Checking lambda probe heating for short circuit to ground........................................................................ 164 Checking manifold absolute pressure sensor for short circuit to ground.......................................................... 165 Checking manifold absolute pressure sensor for short circuit to plus.............................................................. 166 Checking intake air temperature sensor for short circuit to ground.................................................................... 167 Checking intake air temperature sensor for short circuit to plus........................................................................ 168 Checking coolant temperature sensor for short circuit to ground........................................................................ 169 Checking coolant temperature sensor for short circuit to plus ........................................................................... 169 Checking throttle position sensor for short circuit to ground........................................................................ 170 Checking throttle position sensor for short circuit to plus ........................................................................... 172 Checking lambda probe for malfunction in circuit........... 173 Checking injection valve............................................... 174 Checking throttle grip sensor for short circuit to ground........................................................................ 175 Checking throttle grip sensor for short circuit to plus....... 176 Checking ignition pulse generator.................................. 177 Checking primary winding of ignition coil....................... 179 Checking secondary air valve ........................................ 180 Checking fuel evaporation valve .................................... 181 EFI control unit and EPT control unit - checking voltage supply ........................................................................ 182 Rebooting EFI control unit............................................ 183 Checking ambient air pressure sensor for short circuit to ground.................................................................... 183 Checking ambient air pressure sensor for short circuit to plus........................................................................ 184 Checking fuel pump for short circuit to ground............... 185 Checking Hall sensor throttle stepper motor ................... 186 EFI control unit and EPT control unit - checking control signal line................................................................... 187 Checking sidestand switch for short circuit to ground...... 188 Checking rollover sensor for short circuit to ground ......... 189 Checking rollover sensor for short circuit to plus............. 190 Checking CAN-Bus communication ............................... 191 Checking throttle stepper motor .................................... 193 Checking throttle valve position .................................... 196 TECHNICAL DATA - ENGINE............................................ 203 Capacity- engine oil ..................................................... 203 Capacity - coolant........................................................ 203 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE ......................................................................... 204 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 206 TECHNICAL DATA - CHASSIS .......................................... 208 Lighting equipment ..................................................... 208 Capacity - fuel............................................................. 209 TECHNICAL DATA - FORK................................................ 210 TECHNICAL DATA - SHOCK ABSORBER ........................... 211 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 212 CLEANING/CONSERVATION............................................. 214 Cleaning motorcycle .................................................... 214 Conservation for winter operation .................................. 215 STORAGE ....................................................................... 216 Storage....................................................................... 216 Putting into operation after storage ............................... 216 SERVICE PLAN ............................................................... 217 Important service tasks to be carried out by an authorized KTM workshop. ........................................... 217 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order).............. 218 WIRING DIAGRAM .......................................................... 220 1 of 3......................................................................... 220 2 of 3......................................................................... 224 3 of 3......................................................................... 228 SUBSTANCES................................................................. 231 AUXILIARY SUBSTANCES................................................ 233 SPECIAL TOOLS.............................................................. 235 STANDARDS................................................................... 246 INDEX ............................................................................ 247
MEANS OF REPRESENTATION 5 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained in the following. Name Indicates a proprietary name. Protected name® Identifies a protected name. Trademark™ Identifies a brand in merchandise traffic.
IMPORTANT NOTES 6 Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; otherwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle. Fuel, oils, etc. You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage. You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com Work rules During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. If a thread lock (e.g. Loctite® ) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Following repairs or servicing, the vehicle must be checked for roadworthiness. Notes/warnings Pay close attention to the notes/warning. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss- ing, you or others may not recognize dangers and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that will possibly lead to light injury if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. Repair manual – Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and service your motorcycle. – This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.
LOCATION OF SERIAL NUMBERS 7 3.1Chassis number/type label (690 SUPERMOTO R EU/AUS/UK, 690 Supermoto) 500006-01 The chassis number  is stamped on the right of the steering head. The type label  is on the right of the frame behind the steering head. 3.2Chassis number/type label (690 Supermoto R USA) 500006-01 The chassis number  is stamped on the right of the steering head. The USA type label  is on the right of the frame behind the steering head. 500235-10 The Canada type label  is on the right of the frame behind the steering head. 3.3Key number 100179-10 The key number  can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 3.4Engine number 500001-01 The engine number  is stamped on the left side of the engine under the engine sprocket.
LOCATION OF SERIAL NUMBERS 8 3.5Fork part number 700126-01 The fork part number  is stamped on the inner side of the fork stub. 3.6Shock absorber part number 100185-10 (690 Supermoto) The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring on the engine side. 700128-01 (690 Supermoto R) The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring toward the rear.
MOTORCYCLE 9 4.1Jacking up rear of motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. 500238-01 – Insert the work stand adapter in the work stand and screw it into the link forks. Work stand adapter (61029055110) ( p. 237) Work stand rear (61029055100) ( p. 237) – Stand the motorcycle upright, align the work stand to the rear, and jack up the motorcycle. 4.2Jacking up the middle of the motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. 300559-10 – Remove the nuts  on both sides. – Take off the footrest rubber and holder. 300560-10 – Mount the special tool  and . Work stand (62529055000) ( p. 238) Work stand adapter (75029036000) ( p. 239) – Jack up the motorcycle. 4.3Jacking up front of motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the rear of the motorcycle. ( p. 9) 500237-01 – Move the handlebar to the straight-ahead position. Align the work stand to the front with the adapters to the fork legs. Work stand front (61029055300) ( p. 237) Info Always jack up the rear of the motorcycle first. – Jack up the front of the motorcycle.
MOTORCYCLE 10 4.4Take the rear from the work stand. Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the work stand from the rear and lean the vehicle on the side stand. 4.5Removing the motorcycle from the work stand Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. 300560-11 – Secure the motorcycle against falling over. – Remove the special tool  and . 300559-11 – Position the footrest rubbers with holders on both sides. – Install nuts  on both sides. Requirement Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) 4.6Taking front from work stand Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the work stand at the front. 4.7Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an effective exhaust extraction system. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged. – Never operate the vehicle with a discharged battery or without a battery. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. – Always warm up the engine at low engine speeds.
MOTORCYCLE 11 100109-10 – Turn the emergency OFF switch to the position . – Switch on the ignition by turning the ignition key to the position (690 SUPER- MOTO R EU/AUS/UK, 690 Supermoto) (690 Supermoto R USA). After switching on the ignition, you can hear the fuel pump working for about 2 seconds. At the same time, the combination instrument runs a function test. – Shift gear to neutral. The green idling speed indicator lamp N  lights up. – Press the electric starter button . Info Do not press the electric starter button until the combination instrument function test is finished. Do not open the throttle when starting. If you open the throttle when start- ing, the engine management injects no fuel and the engine cannot start. Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds until trying again. This motorcycle is equipped with a safety electric starter system. The engine can be started only if the gearbox is in neutral or the clutch lever is pulled. If you shift into gear when the side stand is folded out and then release the clutch lever, the engine stalls. – Take the weight off the side stand and swing it back up with your foot as far as it will go.
01/FORK, TRIPLE CLAMP 12 5.1Adjusting compression damping of fork (690 Supermoto R) Info The hydraulic compression damping determines the fork suspension behavior. 100122-01 – Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise the number of clicks corresponding to the fork type. Requirement Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. 5.2Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork suspension behavior. 100123-10 – Turn adjusting screws  clockwise until they stop. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – Turn back counterclockwise the number of clicks corresponding to the fork type. Requirement Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. 5.3Bleeding fork legs – Lean the motorcycle on the side stand. 100124-10 – Remove bleeder screws  briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs.
01/FORK, TRIPLE CLAMP 13 5.4Removing fork legs – Jack up the middle of the motorcycle. ( p. 9) – Tie the rear of the vehicle down. 200707-10 – Remove screws  and spacers . – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Carefully pull the brake caliper backwards from the brake disc. Info Do not pull the handbrake lever while the brake caliper is removed. 200708-10 – Loosen screws  and . – Unscrew screw  about 6 turns, press your hand on the screw to push the wheel spindle out of the fork stub. Remove screw . Warning Danger of accidents Reduced braking due to damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not dam- aged. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. 200709-10 – Remove screws  with the washers. Remove the splash protector. 200710-10 – Remove the screws of the wheel speed sensor . Hang the wheel speed sensor to one side. – Loosen the cable binders. 200711-10 – Remove screw . Take the brake line and cable harness out of the clamp.
01/FORK, TRIPLE CLAMP 14 200712-10 – Loosen the screws  of the triple clamp. Remove the fork leg downwards. 200713-10 – Loosen the screws  of the triple clamp. Remove the fork leg downwards. 5.5Installing fork legs 200713-11 – Push the fork leg into the triple clamp. Info The bleeder screws must face forwards. The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp. – Tighten the screws  of the triple clamp. Requirement Screw, top triple clamp M8 12 Nm (8.9 lbf ft) Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) 200712-11 – Push the fork leg into the triple clamp. Info The upper fork projection must be the same on both sides. – Tighten the screws  of the triple clamp. Requirement Screw, top triple clamp M8 12 Nm (8.9 lbf ft) Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) 200710-11 – Position the whell speed sensor. Mount and tighten screws . Requirement Screw, wheel speed sensor M4 2 Nm (1.5 lbf ft) Loctite® 243™
01/FORK, TRIPLE CLAMP 15 200711-11 – Position the brake line, cable harness and clamp. – Mount and tighten screw . Requirement Screw, plastic clamp of brake line on fork leg M5 2 Nm (1.5 lbf ft) 200709-10 – Position the splash protector. Mount and tighten screws  with the washers. Requirement Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 200714-10 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean screw  and wheel spindle. – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw . Requirement Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) 200707-11 – Position the brake calipers and check that the brake linings are seated correctly. – Install the screws  with the spacers . Tighten the screws. Requirement Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™ – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Release the rear of the vehicle. – Remove the motorcycle from the work stand. ( p. 10) 200717-10 – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten. – Fully tighten screws . Requirement Screw, fork stub M8 15 Nm (11.1 lbf ft)
01/FORK, TRIPLE CLAMP 16 5.6Dismantling fork legs (690 Supermoto) Info These operations are the same on both fork legs. 200642-10 – Establish and note the current state of the rebound damping . – Fully open the adjusting element of the rebound damping. 200643-10 – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 245) 200644-10 – Loosen the screw cover . Info The screw cover cannot be removed yet. 200645-10 – Release the fork leg and clamp it with the fork stub. Info Use soft jaws. 200646-01 – Push the outer tube downward. – Pull the spring downwards. Mount the special tool on the hexagon. Open-end wrench (T14032) ( p. 245) Info The pretensioning bushes  should be above the special tool.
01/FORK, TRIPLE CLAMP 17 200647-01 – Clamp the special tool in the vise. Loosen the screw cover . 200648-01 – Remove the screw  cover with the pretensioning bushes . – Remove the adjusting tube . 200649-01 – Pull the spring downwards. Remove the special tool. – Remove the spring. 200650-01 – Empty the fork oil. Info Pull out and push in the piston rod a few times to empty the cartridge. 200651-01 – Clamp the fork leg with the fork stub. – Remove the screws  of the fork stub. 200652-01 – Loosen the screw  of the cartridge and remove it with the sealing ring. Info Place a container underneath to catch any oil that may run out.
01/FORK, TRIPLE CLAMP 18 200653-01 – Remove the cartridge. 200654-01 – Remove the valve  of the rebound damping with the spring from the cartridge. 200655-01 – Remove the dust boot . 200656-01 – Remove the lock ring . Info The lock ring has a beveled end where a screwdriver can be applied. 200657-01 – Heat up the outer tube in the area  of the lower sliding bushing. Requirement 50 °C (122 °F) – Pull the fork outer tube with a jerk from the inner tube. Info The lower sliding bushing  must be pulled from its bearing seat. 200658-01 – Remove the upper sliding bushing . Info Do not use tools, but carefully pull the stack apart by hand.
01/FORK, TRIPLE CLAMP 19 200659-01 – Take off the lower sliding bushing . – Take off the support ring . – Take off the seal ring . – Take off the lock ring . – Take off the dust boot . 5.7Assembling fork legs (690 Supermoto) Info These operations are the same on both fork legs. – Check the fork. ( p. 30) 200669-10 – Clamp the inner tube with the fork stub. – Install the special tool. Protecting sleeve (T1401) ( p. 244) – Grease and push on the dust boot . Lubricant (T511) ( p. 233) Info Always replace the dust boot, the seal ring, the lock ring, and the support ring. Install the dust boot with the sealing lip and hose spring facing downward. – Push on the lock ring . – Grease and push on the seal ring . Lubricant (T511) ( p. 233) Info Sealing ring downward, open side upward. – Push on the support ring . – Remove the special tool. 200670-10 – Sand the edges of the sliding bushes with 600-grain sandpaper, then clean and grease them. Fork oil (SAE 5) ( p. 232) 200671-10 – Push on the lower sliding bushing . – Install the upper sliding bushing . Info Do not use tools, but carefully pull the stack apart by hand.
01/FORK, TRIPLE CLAMP 20 200672-12 – Push on the outer tube. – Heat up the outer tube in the area  of the lower sliding bushings. Requirement 50 °C (122 °F) – Hold the lower sliding bushing with the longer side of the special tool. Assembly tool (T1402S) ( p. 244) – Press on the outer tube as far as it will go. 200673-10 – Position the support ring. – Hold the seal ring with the shorter side of the special tool. Assembly tool (T1402S) ( p. 244) – Press on the outer tube as far as it will go. 200656-11 – Mount lock ring . Info The lock ring must engage audibly. 200655-11 – Install the dust boot . 200674-10 – Grease the O-ring of the valve  of the rebound damping. Lubricant (T158) ( p. 233) – Mount the valve  of the rebound damping with the spring on to the adjusting tube . – Mount the valve  of the rebound damping from below in the cartridge . The adjusting tube protrudes 5 mm from the cartridge and can be pressed in against the resistance of the spring. The adjusting tube protrudes more than 7 mm from the cartridge and cannot be pressed in against the resistance of the spring. – Screw on the hydrostop  as far as it will go. Info The hydrostop must be tightened as much as possible. Do not use tools.
01/FORK, TRIPLE CLAMP 21 200675-10 – Install the special tool on the cartridge. Gripping tool (T14026S1) ( p. 244) Info The special tool must be used to prevent the adjusting tube being lifted and thus to prevent oil from reaching the piston rod. 200676-10 – Push the cartridge with the spring cap and pretensioning bush into the inner tube. – Install the screw  of the cartridge with the sealing ring and tighten it. Requirement Cartridge screw M12x1 25 Nm (18.4 lbf ft) 200651-11 – Grease and install the screws  of the fork stub, but do not tighten them. Lubricant (T152) ( p. 233) 200677-10 – Clamp the fork vertically. – Fill it with fork oil. Fork oil 670 ml (22.65 fl. oz.) Fork oil (SAE 5) ( p. 232) Info Pull out and push in the piston rod completely a few times to remove air from the cartridge. 200678-10 – Remove the pin  of the special tool. Gripping tool (T14026S1) ( p. 244) – Pull out the piston rod. Install the spring. Install the spring again. Requirement Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 5.2 N/mm (29.7 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 5.6 N/mm (32 lb/in) 200679-10 – Pull the spring downwards. Mount the special tool on the hexagon. Open-end wrench (T14032) ( p. 245) – Remove the special tool. Gripping tool (T14026S1) ( p. 244)
01/FORK, TRIPLE CLAMP 22 200680-10 – Clamp the special tool in the vise. – Grease the thread of the piston rod. Lubricant (T159) ( p. 234) – Grease the upper edge of the piston rod. Lubricant (T158) ( p. 233) – Screw the screw cover with the pretensioning bush on to the piston rod. Info The screw cover must be screwed to the stop before the piston rod starts to turn. If the thread of the piston rod is stiff, it must be held to prevent it from turning. If the screw cover is not screwed to the stop, the rebound adjustment does not work correctly. – Tighten the screw cover. Requirement Screw cover on piston rod M12x1 25 Nm (18.4 lbf ft) 200646-11 – Release the special tool. Pull the spring downward and take off the special tool. 200681-10 – Push the outer tube upward. – Clamp the fork in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 245) – Grease the O-ring of the screw cover. Lubricant (T511) ( p. 233) – Screw on and tighten the screw cover. Requirement Screw cover on outer tube M51x1.5 50 Nm (36.9 lbf ft) 200642-11 Alternatively 1 – Turn the adjusting screw of the rebound  clockwise as far as possible. – Turn back counterclockwise the number of clicks corresponding to the fork leg type. Requirement Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks
01/FORK, TRIPLE CLAMP 23 Alternatively 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Make settings within the recommended range only. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Turn the adjusting screw to the position it was in before dismantling. 5.8Dismantling fork legs (690 Supermoto R) Info These operations are the same on both fork legs. 200660-01 – Establish and note the current state of the rebound damping  and compression damping . – Fully open the adjusting elements of the rebound damping and compression damp- ing. 200643-10 – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 245) 200644-12 – Loosen the screw cover . Info The screw cover cannot be removed yet. 200661-01 – Release the fork leg and clamp it with the fork stub. Info Use soft jaws.
01/FORK, TRIPLE CLAMP 24 200646-12 – Push the outer tube downward. – Pull the spring downwards. Mount the special tool on the hexagon. Open-end wrench (T14032) ( p. 245) Info The pretensioning bushes  should be above the special tool. 200647-12 – Clamp the special tool in the vise. Loosen the screw cover . 200648-12 – Remove the screw  cover with the pretensioning bushes . – Remove the adjusting tube . 200649-01 – Pull the spring downwards. Remove the special tool. – Remove the spring. 200650-01 – Empty the fork oil. Info Pull out and push in the piston rod a few times to empty the cartridge. 200662-01 – Clamp the fork leg with the fork stub. – Remove the screws  of the fork stub.
01/FORK, TRIPLE CLAMP 25 200667-10 – Loosen the screw  of the cartridge and remove it with the sealing ring. Info Place a container underneath to catch any oil that may run out. 200653-01 – Remove the cartridge. 200654-12 – Remove the valve  of the rebound damping with the spring from the cartridge. 200655-12 – Remove the dust boot . 200656-12 – Remove lock ring . Info The lock ring has a beveled end where a screwdriver can be applied. 200668-10 – Heat up the outer tube in the area  of the lower sliding bushings. Requirement 50 °C (122 °F) – Pull the fork outer tube with a jerk from the inner tube. Info The lower sliding bushing  must be pulled from its bearing seat.
01/FORK, TRIPLE CLAMP 26 200658-12 – Remove the upper sliding bushing . Info Do not use tools, but carefully pull the stack apart by hand. 200659-12 – Take off the lower sliding bushing . – Take off the support ring . – Take off the seal ring . – Take off the lock ring . – Take off the dust boot . 5.9Assembling fork legs (690 Supermoto R) Info These operations are the same on both fork legs. – Check the fork. 200669-10 – Clamp the inner tube with the fork stub. – Install the special tool. Protecting sleeve (T1401) ( p. 244) – Grease and push on the dust boot . Lubricant (T511) ( p. 233) Info Always replace the dust boot, the seal ring, the lock ring, and the support ring. Install the dust boot with the sealing lip and hose spring facing downward. – Push on the lock ring . – Grease and push on the seal ring . Lubricant (T511) ( p. 233) Info Sealing ring downward, open side upward. – Push on the support ring . – Remove the special tool. 200670-10 – Sand the edges of the sliding bushes with 600-grain sandpaper, then clean and grease them. Fork oil (SAE 5) ( p. 232)
01/FORK, TRIPLE CLAMP 27 200671-10 – Push on the lower sliding bushing . – Install the upper sliding bushing . Info Do not use tools, but carefully pull the stack apart by hand. 200672-10 – Push on the outer tube. – Heat up the outer tube in the area  of the lower sliding bushings. Requirement 50 °C (122 °F) – Hold the lower sliding bushing with the longer side of the special tool. Assembly tool (T1402S) ( p. 244) – Press on the outer tube as far as it will go. 200673-10 – Position the support ring. – Hold the seal ring with the shorter side of the special tool. Assembly tool (T1402S) ( p. 244) – Press on the outer tube as far as it will go. 200656-11 – Mount lock ring . Info The lock ring must engage audibly. 200655-11 – Install the dust boot . 200674-10 – Grease the O-ring of the valve  of the rebound damping. Lubricant (T158) ( p. 233) – Mount the valve  of the rebound damping with the spring on to the adjusting tube . – Mount the valve  of the rebound damping from below in the cartridge . The adjusting tube protrudes 5 mm from the cartridge and can be pressed in against the resistance of the spring. The adjusting tube protrudes more than 7 mm from the cartridge and cannot be pressed in against the resistance of the spring.
01/FORK, TRIPLE CLAMP 28 – Screw on the hydrostop  as far as it will go. Info The hydrostop must be tightened as much as possible. Do not use tools. 200675-10 – Install the special tool on the cartridge. Gripping tool (T14026S1) ( p. 244) Info The special tool must be used to prevent the adjusting tube being lifted and thus to prevent oil from reaching the piston rod. 200683-10 – Push the cartridge with the spring cap and pretensioning bush into the inner tube. – Install the screw  of the cartridge with the sealing ring and tighten it. Requirement Cartridge screw M12x1 25 Nm (18.4 lbf ft) 200682-10 – Grease and install the screws  of the fork stub, but do not tighten them. Lubricant (T152) ( p. 233) 200677-10 – Clamp the fork vertically. – Fill it with fork oil. Fork oil 680 ml (22.99 fl. oz.) Fork oil (SAE 5) ( p. 232) Info Pull out and push in the piston rod completely a few times to remove air from the cartridge. 200678-10 – Remove the pin  of the special tool. Gripping tool (T14026S1) ( p. 244) – Pull out the piston rod. Install the spring. Install the spring again. Requirement Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 5.2 N/mm (29.7 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 5.6 N/mm (32 lb/in)
01/FORK, TRIPLE CLAMP 29 200679-10 – Pull the spring downwards. Mount the special tool on the hexagon. Open-end wrench (T14032) ( p. 245) – Remove the special tool. Gripping tool (T14026S1) ( p. 244) 200680-10 – Clamp the special tool in the vise. – Grease the thread of the piston rod. Lubricant (T159) ( p. 234) – Grease the upper edge of the piston rod. Lubricant (T158) ( p. 233) – Screw the screw cover with the pretensioning bush on to the piston rod. Info The screw cover must be screwed to the stop before the piston rod starts to turn. If the thread of the piston rod is stiff, it must be held to prevent it from turning. If the screw cover is not screwed to the stop, the rebound adjustment does not work correctly. – Tighten the screw cover. Requirement Screw cover on piston rod M12x1 25 Nm (18.4 lbf ft) 200646-11 – Release the special tool. Pull the spring downward and take off the special tool. 200681-10 – Push the outer tube upward. – Clamp the fork in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 245) – Grease the O-ring of the screw cover. Lubricant (T511) ( p. 233) – Screw on and tighten the screw cover. Requirement Screw cover on outer tube M51x1.5 50 Nm (36.9 lbf ft) 200660-11 Alternatively 1 – Turn the adjusting screw of the rebound  and the adjusting screw of the com- pression damping  clockwise as far as possible.
01/FORK, TRIPLE CLAMP 30 – Turn back counterclockwise the number of clicks corresponding to the fork leg type. Requirement Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Alternatively 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Make settings within the recommended range only. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Turn the adjusting screws to the position they were in before dismantling. 5.10Checking fork Condition Fork dismantled. 200686-10 – Check the inner tube and the fork stub for damage. » If damage is found: – Replace the inner tube. 200684-10 – Measure the external diameter of the inner tube in several places. External diameter of inner tube 47.975… 48.005 mm (1.88878… 1.88996 in) » If the measured value is less than the specified value: – Replace the inner tube. 200685-10 – Measure the run-out of the inner tube. Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in) » If the measured value is greater than the specified value: – Replace the inner tube.
01/FORK, TRIPLE CLAMP 31 200632-10 – Check the outer tube for damage. » If damage is found: – Replace the outer tube. 200665-10 – Check the surface of the sliding bushings. » If the bronze-colored layer  under the sliding layer  is visible: – Replace the sliding bushings. 200666-10 – Check the spring length. Requirement Spring length with preload spacer(s) 430 mm (16.93 in) » If the measured value is greater than the specified value: – Reduce the strength of the pretensioning bushes. » If the measured value is less than the specified value: – Increase the strength of the pretensioning bushes.
04/SHOCK ABSORBER, SWINGARM 32 6.1Adjusting high-speed compression damping of the shock absorber (690 Supermoto R) Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself. Info The high-speed setting can be seen during the fast compression of the shock absorber. 100126-10 – Turn the adjusting screw  clockwise with an open-ended spanner until it stops. Info Do not loosen nut ! – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Requirement Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn full payload 1 turn Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. 6.2Adjusting the low-speed compression damping of the shock absorber (690 Supermoto R) Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself. Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. 100125-10 – Turn the adjusting screw  clockwise with a screwdriver up to the last perceptible click. Info Do not loosen nut ! – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Requirement Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.
04/SHOCK ABSORBER, SWINGARM 33 6.3Adjusting rebound damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself. 100127-10 – Turn the adjusting screw  clockwise up to the last perceptible click. – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Requirement Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. 6.4Removing the shock absorber – Jack up the middle of the motorcycle. ( p. 9) 300555-10 – Loosen screw . 300556-10 – Remove the nut  with the screw. – Swing the connecting lever  downwards. 300557-10 – Lift the link fork. – Loosen screw . – Remove the nut  with the screw. – Remove the screw  and take off the deflector.
04/SHOCK ABSORBER, SWINGARM 34 300555-10 – Remove screw . 300558-10 – Lift the link fork and take out the shock absorber  downwards. 6.5Installing shock absorber 300558-11 – Lift the link fork and insert the shock absorber  upwards. 300555-11 – Mount screw  but do not tighten it yet. Requirement Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™ 300561-10 – Lift the link fork. – Position the deflector. – Mount screw with nut  but do not tighten it yet. Requirement Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) – Mount screw  but do not tighten it yet. Requirement Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™ – Position the connecting lever . – Mount and tighten screw with nut . Requirement Nut, frame to linkage lever M14x1.5 100 Nm (73.8 lbf ft) – Tighten nut  and screw .
04/SHOCK ABSORBER, SWINGARM 35 300555-11 – Tighten screw . Requirement Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™ – Remove the motorcycle from the work stand. ( p. 10) 6.6Removing spring (690 Supermoto) – Remove the shock absorber. ( p. 33) 300378-10 – Clamp the shock absorber in the vise using soft jaws for protection. – Measure and note spring length  in preloaded state. 300428-10 – Loosen the counter ring  and the adjusting ring with the special tool . Hook wrench (T106) ( p. 243) – Turn the counter ring and adjusting ring until they are at the top. 300429-10 – Press down the spring with the special tool. Spring compressor (T101S) ( p. 243) – Remove the spring retainer . 300430-10 – Take off the spring  with the counter ring and the adjusting ring .
04/SHOCK ABSORBER, SWINGARM 36 6.7Installing shock absorber (690 Supermoto) 300426-10 – Clamp the shock absorber in the vise using soft jaws. – Install the counter ring  and turn it downward as far as possible. The collar faces the adjusting ring. – Install the adjusting ring  and turn it downward as far as possible. The collar faces the spring. – Measure the overall spring length when not under tension. – Install the spring. Requirement Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 60 N/mm (343 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 65 N/mm (371 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 70 N/mm (400 lb/in) 300429-10 – Tension the spring with the special tool. Spring compressor (T101S) ( p. 243) – Install the spring retainer . The open end is opposite the end of the spring. 300428-11 Alternatively 1 – Tension the spring by turning the adjusting ring to the prescribed value. Requirement Spring preload 12 mm (0.47 in) Hook wrench (T106) ( p. 243) Alternatively 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Make settings within the recommended range only. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Tension the spring to its original value before dismantling by turning the adjust- ing ring. Hook wrench (T106) ( p. 243) – Turn the counter nut  and adjusting ring. – Install the shock absorber. ( p. 34)
04/SHOCK ABSORBER, SWINGARM 37 6.8Dismantling shock absorber (690 Supermoto) – Remove the spring. ( p. 35) 300431-10 – Clamp the shock absorber in the vise using soft jaws. – Make a note of the current state of the rebound damping. – Completely open the rebound damping. – Remove screw . The nitrogen gas pressure is released. Info The screw of the filling port must be at the highest position. – Drain the oil. 300432-10 – Remove the locking cap . 300433-10 – Press in the seal ring carrier . Remove lock ring . Info Do not scratch the inner surface. 300434-10 – Remove the piston rod. Drain the remaining oil. 6.9Assembling shock absorber (690 Supermoto) 300441-10 – Install the screw of the filling port with a new seal and tighten it. Requirement Filling port screw M5 3 Nm (2.2 lbf ft) – Fill the shock absorber tube. Requirement Fluid level below upper rim 80 mm (3.15 in) Shock absorber oil (SAE 2.5) (50180342S1) ( p. 232)
04/SHOCK ABSORBER, SWINGARM 38 300442-10 – Install the piston ring  in the piston ring groove and lubricate it. – Grease the O-ring of the seal ring carrier. Lubricant (T158) ( p. 233) – Carefully mount the piston rod. 300443-10 – Press in the seal ring carrier . – Mount lock ring . Info Insert the closed part of the lock ring before the two ends to prevent scratching the surface of the shock absorber tube below the groove and damaging the O-ring during fitting or operation. – Pull out the piston rod until the seal ring carrier is in contact with the lock ring. 300444-10 – Install the locking cap  with a plastic hammer. – Fill the shock absorber with nitrogen. ( p. 39) 300458-10 Alternatively 1 – Turn the adjusting screw  to the right as far as possible. – Turn back to the left the number of clicks corresponding to the shock absorber type. Requirement Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Alternatively 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Make settings within the recommended range only. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Turn the adjusting screw  to the position it was in before dismantling. – Install the shock absorber. ( p. 36)
04/SHOCK ABSORBER, SWINGARM 39 6.10Filling shock absorber with nitrogen (690 Supermoto) 300423-10 – Fix the special tool  in the vise. – Install the special tool . Nitrogen filling tool (T170S1) ( p. 245) 300571-10 – Loosen the screw of the filling port about 2 turns. – Point the screw of the filling port upward and push the piston rod in the shock absorber tube until the oil starts to run out. 300459-10 – Connect the filling cylinder to the connection . Filling gas - nitrogen – Adjust the pressure regulator . Requirement Gas pressure 12 bar (174 psi) – Position the shock absorber in the special tool. The hexagon of the tap handle  engages in the hexagon socket of the filling port screw. – Open the filler tap . The piston rod is pushed out during filling. Info The filler tap opens when the sleeve is pushed on to the special tool  and closes when it is withdrawn from the special tool. If nitrogen escapes, the shock absorber must be pressed harder against the seal of the special tool . – Fill the shock absorber for at least 15 seconds. Requirement Gas pressure 12 bar (174 psi) Info Watch the display of the pressure regulator. Make sure that the shock absorber is filled to the specified pressure. – Close the screw of the filling port using the tap handle . – Close the filler tap and take the shock absorber out of the special tool. – Tighten the screw of the filling port. Requirement Filling port screw M5 3 Nm (2.2 lbf ft)
04/SHOCK ABSORBER, SWINGARM 40 6.11Disassembling piston rod (690 Supermoto) – Dismantle the shock absorber. ( p. 37) 300435-10 – Clamp the piston rod with the heim joint in a vise. – Remove nut . 300436-10 – Remove the supporting plate  and the rebound shim set  together with the pis- ton . Info Thread the rebound shim set on a screwdriver and take the parts off together. 300437-10 – Remove the compression damping shim set . Info Thread the compression damping shim set on a screwdriver and take the parts off together. 300439-10 – Remove the supporting plate . – Remove the seal ring carrier . 300390-10 – Remove the locking cap  and rubber buffer plug .
04/SHOCK ABSORBER, SWINGARM 41 6.12Assembling piston rod (690 Supermoto) 300410-10 – Clamp the piston rod with the heim joint in a vise. – Install the rubber buffer plug  and locking cap . 300411-10 – Position special tool  on the piston rod. Mounting sleeve (T1215) ( p. 244) – Grease the seal ring and push the seal ring carrier  on to the piston rod. Lubricant (T625) ( p. 234) – Remove the special tool. 300412-10 – Install the supporting plate  with the rounded side to the front. 300413-10 – Install the compression damping shim set . Info The compression damping shim set must be installed with the smaller shims facing downwards. 300415-10 – Sand both sides of the piston on a surface plate using grain 1200 sandpaper. Info View of piston from above . View of piston from below . – Clean the piston. 300414-10 – Assemble the piston.
04/SHOCK ABSORBER, SWINGARM 42 300416-10 – Install the rebound shim set . Info The rebound shim set must be installed with the smaller shims facing upwards. 300417-10 – Install the supporting plate . 300418-10 – Mount and tighten the nut. Requirement Piston rod nut M12x1 40 Nm (29.5 lbf ft) – Assemble the shock absorber. ( p. 37) 6.13Removing spring (690 Supermoto R) – Remove the shock absorber. ( p. 33) – Clamp the shock absorber in the vise using soft jaws for protection. – Measure and note spring length in preloaded state. 300531-10 – Loosen the counter ring  and the adjusting ring with the special tool. Hook wrench (T106) ( p. 243) – Turn the counter ing and the adjusting ring until the spring is fully relieved of ten- sion. 300532-10 – Press down the spring with the special tool. Spring compressor (T101S) ( p. 243) – Remove the spring retainer .
04/SHOCK ABSORBER, SWINGARM 43 300533-10 – Take off the spring  with the counter ring and the adjusting ring . 6.14Installing spring (690 Supermoto R) 300531-11 – Clamp the shock absorber in the vise using soft jaws. – Install the counter ring  and turn it downward as far as possible. The collar faces the adjusting ring. – Install the adjusting ring  and turn it downward as far as possible. The collar faces the spring. – Measure the overall spring length when not under tension. – Install the spring. Requirement Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 60 N/mm (343 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 65 N/mm (371 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 70 N/mm (400 lb/in) 300532-11 – Tension the spring with the special tool. Spring compressor (T101S) ( p. 243) – Install the spring retainer . The open end is opposite the end of the spring. 300531-10 Alternatively 1 – Tension the spring by turning the adjusting ring to the prescribed value. Requirement Spring preload 12 mm (0.47 in) Hook wrench (T106) ( p. 243) Alternatively 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Make settings within the recommended range only. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Tension the spring to its original value before dismantling by turning the adjust- ing ring. Hook wrench (T106) ( p. 243) – Turn the counter nut  and adjusting ring. – Install the shock absorber. ( p. 34)
04/SHOCK ABSORBER, SWINGARM 44 6.15Dismantling shock absorber (690 Supermoto R) – Remove the spring. ( p. 42) 300534-10 – Establish and note the current state of the rebound damping and compression damping. – Fully open the adjusting elements of the rebound damping and compression damp- ing. – Remove the seal . – Press in the valve needle . The nitrogen gas pressure is released. 300535-10 – Remove the locking cap . 300536-10 – Press in the seal ring carrier . Remove lock ring . Info Do not scratch the inner surface. 300537-10 – Remove screw . Drain the oil. 300538-10 – Remove the piston rod. Drain the remaining oil.
04/SHOCK ABSORBER, SWINGARM 45 300539-10 – Remove the compression damping adjuster . Remove the spring, the sleeve, and the piston. 6.16Assembling shock absorber (690 Supermoto R) 300544-10 – Push the spring and sleeve on to the compression damping adjuster. Attach the piston. – Mount and tighten the compression damping adjuster . Requirement Compression damping adjustment M26x1 30 Nm (22.1 lbf ft) 300537-11 – Mount and tighten screw . Requirement Filling port screw M10x1 14 Nm (10.3 lbf ft) 300549-10 – Half-fill the shock absorber tube. Shock absorber oil (SAE 2.5) (50180342S1) ( p. 232)
04/SHOCK ABSORBER, SWINGARM 46 300545-10 – Grease the O-ring  of the seal ring carrier. Lubricant (T158) ( p. 233) – Carefully mount the piston rod. 300536-10 – Install the seal ring carrier  and push it under the ring groove. – Mount lock ring . Info Do not scratch the inner surface. – Pull out the piston rod so that the seal ring carrier is in contact with the lock ring. 300546-10 – Install the locking cap  of the shock absorber tube. – Bleed and fill the shock absorber. ( p. 47) – Fill the shock absorber with nitrogen. ( p. 49) 300570-10 Alternatively 1 – Turn the adjusting screw  clockwise with a screwdriver up to the last percep- tible click. – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Requirement Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks – Turn the adjusting screw  clockwise with an open-ended spanner until it stops. – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Requirement Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn full payload 1 turn – Turn the adjusting screw  clockwise up to the last perceptible click.
04/SHOCK ABSORBER, SWINGARM 47 – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Requirement Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Alternatively 2 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components. – Make settings within the recommended range only. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. – Turn the adjusting screw , , and  to the position it was in before disman- tling. – Install the spring. ( p. 43) 6.17Bleeding and filling shock absorber (690 Supermoto R) Info Before working with the vacuum pump, make sure you read the vacuum pump operating instructions carefully. Fully open the adjusting elements of the rebound damping and compression damping. 300550-10 – Remove the screw of the filling port. – Install the adapter  on the shock absorber. Info Hand-tighten only, and do not use tools. – Connect the adapter  to the connector  of the vacuum pump. – Clamp the shock absorber with soft jaws or hold it as shown in the photo. Info Clamp the shock absorber only lightly. The filling port must be at the top. The piston rod slides in and out during filling - do not hold it tight with your hand! 200271-10 – Turn the control lever as shown in the photo. The External tank control lever  is set to Closed, Damper  to Vacuum, and Oil reservoir  to Vacuum. – Operate the On/Off switch . The extraction process begins. The pressure gauge  falls to the specified value. < 0 bar The vacuum pressure gauge  falls to the specified value. 8 mbar
04/SHOCK ABSORBER, SWINGARM 48 200267-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser- voir control lever  to Equalize pressure. Requirement 8 mbar The pressure gauge rises to the specified value. 0 bar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever  to Pressure. Requirement 0 bar Oil is pumped into the shock absorber. The pressure gauge rises to the specified value. 3 bar 200269-10 – When the pressure gauge reaches the specified value, turn the Damper control lever  to Vacuum. Requirement 3 bar The pressure gauge falls to the specified value. 0 bar 200270-10 – When the pressure gauge reaches the specified value, turn the Oil reservoir control lever  to Vacuum. Requirement 0 bar The vacuum pressure gauge falls to the specified value. 8 mbar 200267-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser- voir control lever  to Equalize Pressure. Requirement 8 mbar The pressure gauge falls to the specified value. 0 bar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever  to Pressure. Requirement 0 bar Oil is pumped into the shock absorber. The pressure gauge rises to the specified value. 3 bar
04/SHOCK ABSORBER, SWINGARM 49 200269-10 – When the pressure gauge reaches the specified value, turn the Damper control lever  to Vacuum. Requirement 3 bar The pressure gauge falls to the specified value. 0 bar – When the pressure gauge reaches the specified value, operate the On/Off switch. Requirement 0 bar The vacuum pump is switched off. – Disconnect the adapter. Info Hold the shock absorber so that the filling port is at the top. – Remove the filling port. A little oil escapes from the shock absorber. 300551-10 – Mount and tighten screw . Requirement Filling port screw M10x1 14 Nm (10.3 lbf ft) 6.18Filling shock absorber with nitrogen (690 Supermoto R) 300552-10 – Clamp the shock absorber in the vise using soft jaws. – Install the special tool  on to the connector of the shock absorber. Filling adapter (T1516) ( p. 245) Info The piston slides fully out. – Connect the filling cylinder to the connection . Filling gas - nitrogen 300425-11 – Adjust the pressure regulator . Requirement Gas pressure 12 bar (174 psi) 300552-11 – Open the valve . – Fill the shock absorber for at least 15 seconds. Requirement Gas pressure 12 bar (174 psi) Info Watch the display of the pressure regulator. Make sure that the shock absorber is filled to the specified pressure. – Close the valve.
04/SHOCK ABSORBER, SWINGARM 50 – Seal the filling cylinder. – Remove the special tool. Filling adapter (T1516) ( p. 245) – Install the cap. 6.19Disassembling piston rod (690 Supermoto R) – Dismantle the shock absorber. ( p. 44) 300540-10 – Clamp the piston rod with the heim joint in a vise. – Remove nut . 300541-10 – Remove the supporting plate  and the rebound shim set  together with the pis- ton . Info Thread the rebound shim set on a screwdriver and take the parts off together. 200572-11 – Remove the compression damping shim set  with the supporting plate . Info Thread the compression damping shim set on a screwdriver and take the parts off together. 300542-10 – Remove the seal ring carrier . 300543-10 – Remove the locking cap  and rubber buffer plug .
04/SHOCK ABSORBER, SWINGARM 51 6.20Assembling piston rod (690 Supermoto R) 300543-11 – Clamp the piston rod with the heim joint in a vise. – Install the rubber buffer plug  and locking cap . 300548-10 – Position special tool  on the piston rod. Mounting sleeve (T1515) ( p. 245) – Grease the seal ring and push the seal ring carrier  on to the piston rod. Lubricant (T625) ( p. 234) – Remove the special tool. 200572-11 – Mount the supporting plate  and the compression damping shim set . Info Assemble with the rounded side of the supporting plate facing downward. The compression damping shim set must be installed with the smaller shims facing downwards. 300547-10 – Sand both sides of the piston on a surface plate using grain 1200 sandpaper. – Clean the piston. – Assemble the piston. Info The piston is the same on both sides. 300541-11 – Install the rebound shim set  with the supporting plate . Info The rebound shim set must be installed with the smaller shims facing upwards. 300540-11 – Mount and tighten the nut . Requirement Piston rod nut M12x1 40 Nm (29.5 lbf ft) – Assemble the shock absorber. ( p. 45)
04/SHOCK ABSORBER, SWINGARM 52 6.21Removing heim joint – Remove the shock absorber. ( p. 33) 200577-10 – Clamp the shock absorber in the vise using soft jaws for protection. – Remove the flange adaptor  of the heim joint with a drift. – Turn the shock absorber and remove the flange adaptor  of the heim joint with a drift. 200578-10 – Remove seal rings  on both sides. 200579-10 – Remove lock rings  on both sides. 200580-10 – Place special tool  underneath and press out the heim joint with special tool . Pressing tool (T1207S) ( p. 243) 6.22Installing heim joint 200581-10 – Place special tool  underneath and press in the heim joint as far as the center using special tool . Pressing tool (T1206) ( p. 243) Pressing tool (T129) ( p. 244)
04/SHOCK ABSORBER, SWINGARM 53 200579-11 – Install lock rings  on both sides. 200578-11 – Install seal rings  on both sides and grease them. Lubricant (T158) ( p. 233) 200582-10 – Press in both collar sleeves  of the heim joint. – Install the shock absorber. ( p. 34) 6.23Checking shock absorber Condition Shock absorber disassembled. 300440-10 – Measure the internal diameter at both ends and in the center of the shock absorber tube. Shock absorber tube Minimum diameter 46.10 mm (1.815 in) » If the measured value is greater than the specified value: – Change the shock absorber tube. – Check the shock absorber tube for damage and wear. » If there is damage or wear: – Change the shock absorber tube. 300554-10 – Measure the diameter of the piston rod. Piston rod Diameter ≥ 17.95 mm (≥ 0.7067 in) » If the specified value is not met: – Change the piston rod. – Measure the run-out of the piston rod. Piston rod Run-out ≤ 0.03 mm (≤ 0.0012 in) » If the measured value is greater than the specified value: – Change the piston rod. – Check the piston rod for damage and wear. » If there is damage or wear: – Change the piston rod.
04/SHOCK ABSORBER, SWINGARM 54 300460-01 – Check the heim joint for damage and wear. » If there is damage or wear: – Change the heim joint.
05/EXHAUST 55 7.1Removing exhaust manifold – Remove the seat. ( p. 58) – Dismount the fuel tank. ( p. 58) 300171-10 – Unplug the connector of the lambda probe . Open the cable binder. 300172-10 – Remove screw . – Pull the heat shields downwards. Info Check the absorbing elements. – Repeat the operation on the opposite side. 300173-10 – Remove screws . – Repeat the operation on the opposite side. 300174-10 – Remove the nuts  of the exhaust manifold. Info Do not lose the spacing sleeves. 300175-10 – Loosen the screw of the exhaust bracket . – Take off the exhaust manifold.
05/EXHAUST 56 7.2Installing exhaust manifold 300174-11 – Position the spacing sleeve. – Position the manifold at the front with the seals. – Mount nuts  but do not tighten them yet. 300173-11 – Position the manifold at the rear with the seals. Mount screws  but do not tighten them yet. – Repeat the operation on the opposite side. 300175-11 – Position the exhaust bracket . Distance  according to specifications. Distance to exhaust bracket 3… 5 mm (0.12… 0.2 in) – Tighten the screw. Requirement Screw, exhaust clamp on manifold M8 25 Nm (18.4 lbf ft) Copper paste – Tighten the nuts  evenly. Requirement Nut, manifold on cylinder head M8 25 Nm (18.4 lbf ft) Copper paste – Fully tighten screws . Requirement Screw, exhaust clamp on main silencer M8 25 Nm (18.4 lbf ft) 300171-11 – Plug in the connector of the lambda probe . Secure the cable with the cable binders. 300176-10 – Grease the absorbing elements  slightly to ease assembly.
05/EXHAUST 57 300172-11 – Push the heat shield into the bracket from below. – Mount and tighten screw . Requirement Screw, exhaust heat shield M5 5 Nm (3.7 lbf ft) Loctite® 243™ – Repeat the operation on the opposite side. – Install the fuel tank. ( p. 59) – Mount the seat. ( p. 58)
07/FUEL TANK, SEAT, TRIM 58 8.1Opening filler cap 500023-10 – Lift the cover of the filler cap  and insert the ignition key. – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 8.2Closing filler cap 500023-01 – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover. 8.3Removing the seat 100108-10 – Insert the ignition key in the seat lock  and turn it 45° counterclockwise. – Lift up the seat at the rear, pull it back and remove from above. 8.4Mounting the seat 400155-01 – Suspend the seat on the screw , press the rear downwards and at the same time push it forwards. The two projections  must be inserted into the frame. – Push the locking pin  into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click. – Remove the ignition key from the seat lock. – Finally, check that the seat is correctly mounted. 8.5Dismounting the fuel tank Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
07/FUEL TANK, SEAT, TRIM 59 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. – Remove the seat. ( p. 58) 300166-10 – Remove screw . 300167-10 – Press on metal plate  and disconnect the fuel hose connection. Info Remaining fuel may run out of the fuel hose. 300168-10 – Raise the front of the fuel tank. – Press on metal plate  and disconnect the fuel hose connection. Info Remaining fuel may run out of the fuel hose. – Disconnect electric plug-in connector  of the fuel pump. 300169-10 – Disconnect plug-in connector  of the fuel level indicator. – Take off the fuel tank. 8.6Installing the fuel tank Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
07/FUEL TANK, SEAT, TRIM 60 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. 300169-11 – Position the fuel tank and raise it at the front. – Connect plug-in connector  of the fuel level indicator. 300168-11 – Connect plug-in connector  of the fuel pump. – Connect fuel hose connector  with the new O-ring. – Lower the front of the fuel tank. 300167-11 – Connect fuel hose connector  with the new O-ring. 300166-11 – Install and tighten screw  with rubber sleeve and bearing sleeve. Check that the fuel tank is firmly fixed. Requirement Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) – Check routing of fuel lines. – Mount the seat. ( p. 58) 8.7Reinstalling the fuel tank – Remove the seat. ( p. 58) 100173-10 – Remove screw . Info The fuel lines do not need to be disconnected.
07/FUEL TANK, SEAT, TRIM 61 100174-10 – Lay a cloth  over the subframe and straighten the steering. – Carefully raise the fuel tank and move it backwards. – Place the fuel tank on the vehicle so that the left spoiler is still lying on the com- pensating tank  (see illustration). Place a cloth  between the compensating tank and the spoiler to prevent damage. 8.8Positioning the fuel tank 100174-11 – Remove the cloth  from between the compensating tank and the spoiler. 100175-10 – Carefully move the fuel tank forwards and lower it. – Mount and tighten the screw  with the rubber bushing and bearing sleeve. Check fuel tank for tight fitting. Requirement Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) – Check the routing of the fuel hoses. – Mount the seat. ( p. 58)
09/FRONT WHEEL 62 9.1Removing front wheel – Jack up the rear of the motorcycle. ( p. 9) – Jack up the front of the motorcycle. ( p. 9) 100140-10 – Remove screw  and spacing sleeve . – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Pull the brake caliper carefully back from the brake disc and hang it to one side. Info Do not pull the handbrake lever when the brake caliper is removed. 100141-10 – Loosed screw  and screw . – Screw out screw  about 6 turns, press your hand on the screw to push the wheel spindle out of the fork stub. Remove screw . Warning Danger of accidents Reduced braking due to damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not dam- aged. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. 9.2Fitting front wheel 100142-10 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Check parts for damage and wear. Replace damaged or worn parts. – Clean and grease the thread of the wheel spindle and screw . Long-life grease ( p. 233) – Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and tighten screw . Requirement Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) – Position the brake caliper and check that the brake linings are seated correctly. – Position the spacing sleeves . Mount and tighten screws . Requirement Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™ 100168-10 – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Take the front from the work stand. ( p. 10) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Fully tighten screw . Requirement Screw, fork stub M8 15 Nm (11.1 lbf ft) – Taking rear from work stand. ( p. 10)
09/FRONT WHEEL 63 9.3Checking tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. 500240-01 – Remove dust cap. – Check tire air pressure when tires are cold. Tire air pressure, Solo front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) » If the tire pressure does not meet specifications: – Correct tire pressure. – Mount dust cap. 9.4Tire condition checking Warning Danger of accidents Uncontrollable handling behavior caused by a flat tire. – For your own safety, have damaged tires changed immediately. Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels. – The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle has been run in. Info The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. Worn tires have a negative effect on riding behavior, especially on wet surfaces. 500239-01 – Check the front and rear tire for cuts, penetrations and other damage. » If the tires exhibits cuts, penetrations or other damage: – Change the tires. – Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth ≥ 2 mm (≥ 0.08 in) » If the minimum tread depth is insufficient: – Change the tires.
09/FRONT WHEEL 64 9.5Checking brake discs Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. 100135-10 – Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement . Info Wear reduces the thickness of the brake disc in the area  of the brake disc. Brake discs - wear limit (690 Supermoto) Front 4.0 mm (0.157 in) Rear 4.5 mm (0.177 in) Brake discs - wear limit (690 Supermoto R) Front 3.6 mm (0.142 in) rear 4.5 mm (0.177 in) » If the brake disc thickness is less than the specified value: – Replace the brake disc. – Check the front and rear brake discs for damage, cracks, and deformation. » If damage, cracks, or deformation are visible on the brake disc: – Replace the brake disc.
10/REAR WHEEL 65 10.1Removing rear wheel – Jack up the rear of the motorcycle. ( p. 9) 100144-10 – Remove nut . Remove chain adjuster . Holding the rear wheel, withdraw the wheel spindle . – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. 100145-10 – Pull the rear wheel and brake caliper support  together to the rear until you can swing the brake caliper support to the side. Warning Danger of accidents Reduced braking due to damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not dam- aged. – Take the rear wheel out of the swing arm. Info Do not operate the foot brake when the rear wheel is removed. 10.2Fitting rear wheel Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the footbrake until the pressure point is reached. – Checking the rear hub rubber dampers. ( p. 68) 100146-10 – Check parts for damage and wear. Replace damaged or worn parts. – Remove the bushing . Clean and grease the roll surfaces of the bushing and the shaft seal ring . Long-life grease ( p. 233) – Clean and grease the thread of the wheel spindle and nut . Long-life grease ( p. 233) – Clean the fixing locations on the brake caliper support and swingarm. – Mount the rubber damper and rear sprocket carrier in the rear wheel. – Stand the rear wheel in the swingarm and mount the brake caliper on the brake disc. 100147-10 – Push the brake caliper support and the swingarm  into the fixing location. Lay the chain on the rear sprocket and fit the wheel spindle. Info Fit the chain left and right adjusters  in similar positions.
10/REAR WHEEL 66 – Push the rear whell forwards so that the chain adjusters are located on the adjust- ing screws, and tighten nut . Requirement In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks . Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Taking rear from work stand. ( p. 10) 10.3Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. 100130-10 – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upwards near the vertical rib of the swingarm and measure the chain tension . Info The upper chain section  must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension 5 mm (0.2 in) » If the chain tension does not meet specifications: – Adjust the chain tension. ( p. 66) 10.4Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
10/REAR WHEEL 67 100131-10 – Lean the motorcycle on the side stand. – Shift gear to neutral. – Loosen nut . – Loosen nuts . – Adjust the chain tension by turning the adjusting screws  left and right. Requirement Chain tension 5 mm (0.2 in) Turn the adjusting screws  left and right so that the markings on the left and right chain adjusters  are in the same position relative to the reference marks . The rear wheel is then correctly aligned. Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. – Tighten nuts . – Make sure that the chain adjusters  are fitted correctly on the adjusting screws . – Tighten nut . Requirement Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters  can be turned by 180°. 10.5Checking chain wear 700152-01 – Shift into neutral, and pull the lower chain section with the specified weight . Requirement Weight of chain wear measurement 15 kg (33 lb.) – Measure distance  of 18 chain segments of the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance  at the longest section of the chain 272 mm (10.71 in) » If distance  is greater than the specified measurement: – Have the chain changed. Info When the chain is replaced, the rear sprocket and engine sprocket should be replaced at the same time. A new chain will wear faster on an old, worn rear sprocket or engine sprocket. For safety reasons, the chain has no chain joint. Always have the chain changed in an authorized KTM workshop, where they have the necessary special tools.
10/REAR WHEEL 68 10.6Checking rear sprocket / engine sprocket for wear 100132-10 – Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Replace rear sprocket / engine sprocket. Info The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. – Check chain guides for tightness and wear. 10.7Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations. Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 233) – After drying, apply chain spray. Onroad chain spray ( p. 234) 10.8Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. – Remove the rear wheel. ( p. 65) 100148-10 – Check rubber dampers  of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: – Change all rubber dampers in the rear hub.
10/REAR WHEEL 69 100149-10 – Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub. – To check the play , hold the rear wheel tight and try to rotate the rear sprocket. Info Measure the play on the outside of the rear sprocket. Play in rubber dampers, rear wheel ≤ 5 mm (≤ 0.2 in) » If the play  is more than the specified value: – Change all rubber dampers in the rear hub. – Fit the rear wheel. ( p. 65) 10.9Checking spoke tension (690 Supermoto) Warning Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. 100171-10 – To check spoke tension, tap each spoke with a screwdriver. Requirement You should hear a high note. Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft) Info If you hear different tone frequencies from different spokes, this is an indi- cation of different spoke tensions.
11/WIRING HARNESS, BATTERY 70 11.1Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms. – In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician. – Remove the seat. ( p. 58) – Reinstall the fuel tank. ( p. 60) 100169-10 – Disconnect the negative (minus) cable of the battery. – Detach and remove the rubber band . – Take off the positive terminal cover . – Disconnect the positive (plus) cable of the battery. – Pull the battery to the right out of the battery rack. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components can safety equipment can be dam- aged. The vehicle is then no longer safe to ride. 11.2Installing the battery 100169-11 – Push the battery from the right into the battery rack. Info The battery terminals must be at the front. – Secure the battery with the rubber band . – Attach the positive cable and replace the positive terminal cover. – Attach the minus cable . – Position the fuel tank. ( p. 61) – Mount the seat. ( p. 58) – Set the clock. ( p. 78) 11.3Disconnecting negative (minus) cable of battery Condition Fuel tank is reset or removed. 300170-10 – Disconnect the negative (minus) cable  of the battery. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety equipment can be dam- aged. The vehicle is then no longer safe to ride.
11/WIRING HARNESS, BATTERY 71 11.4Reconnecting negative (minus) cable of battery Condition Fuel tank is reset or removed. 300170-10 – Reconnect minus cable . 11.5Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms. – In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician. Warning Environmental hazard Components and battery acid are a danger to the environment. – Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator. Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations. Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced. If the battery is discharged from starting, it must be recharged immediately. If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed. The battery is maintenance-free, i.e., the acid level does not have to be checked. – Switch off all power-consuming components and switch off the engine. – Reinstall the fuel tank. ( p. 60) – Disconnect the minus (negative) cable of the battery to avoid damage to the motor- cycle's electronics.
11/WIRING HARNESS, BATTERY 72 100151-10 – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the bat- tery. Info Never remove the lid . Charge the battery according to the instructions  on the battery casing. – Switch off the charger after charging. Disconnect the battery. Requirement The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use. 3 months – Position the fuel tank. ( p. 61) – Mount the seat. ( p. 58) – Set the clock. ( p. 78) 11.6Changing the main fuse Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power-consuming components of the vehicle. It is in the housing of the starter relay next to the bat- tery. – Switch off all power-consuming components and switch off the engine. – Remove the seat. ( p. 58) – Reinstall the fuel tank. ( p. 60) 100152-10 – Remove protective cover . – Remove a defective main fuse  with a needle nose plier. – Check the parts for damage and wear. Replace damaged or worn parts. Info A reserve fuse  is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p. 208) Info If the new fuse burns out, contact an authorized KTM workshop. – Replace the protective cover. – Position the fuel tank. ( p. 61) – Mount the seat. ( p. 58) – Set the clock. ( p. 78)
11/WIRING HARNESS, BATTERY 73 11.7Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. – Switch off all power-consuming components and switch off the engine. – Remove the seat. ( p. 58) 100153-10 – Open the fuse box cover . 100154-10 – Remove defective fuse. Requirement Fuse 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10A - clock, ignition (EFI control unit) Fuse 3 - 10A - throttle valve control unit Fuse 4 - 10A - fuel pump Fuse 5 - 10A - radiator fan Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional) Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp Fuse 8 - 10A - for supplementary equipment (accessories connected with igni- tion switch) Fuse 9 - 10A - for supplementary equipment (standard accessories) Fuse 10 - not used Fuse SPARE - 10A/15A - spare fuses – Check parts for damage and wear. Replace damaged or worn parts. Info A defective fuse is shown by a burned-out fuse wire . Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 208) Fuse (75011088015) ( p. 208) Info If the new fuse burns out, contact an authorized KTM workshop. Tip Replace the spare fuse in the fuse box so that it will be available if needed. – Check the functioning of the power consumer. – Close the fuse box cover. – Mount the seat. ( p. 58)
13/BRAKE SYSTEM 74 12.1Checking the front brake linings Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. 100137-10 – Check the brake linings for minimum thickness . Minimum thickness  ≥ 1 mm (≥ 0.04 in) » If the minimum thickness is less than specified: – Change the front brake linings. 12.2Adjusting basic position of handbrake lever 100117-10 – Adjust the basic setting of the handbrake lever to your hand size by turning adjust- ing wheel . Info Pull the brake lever forwards and turn the adjusting wheel. Do not make any adjustments while riding! 12.3Checking front brake fluid level Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 100136-10 (690 Supermoto) – The brake fluid level must not fall below the center of the level viewer  when the brake fluid reservoir is vertical. » If the brake fluid level is lower than the center of the level viewer: – Add brake fluid for the front brake. ( p. 75)
13/BRAKE SYSTEM 75 100134-10 (690 Supermoto R) – The brake fluid level must not fall below the MIN marking  when the brake fluid reservoir is vertical. » If the brake fluid is below the MIN marking: – Add brake fluid for the front brake. ( p. 75) 12.4Adding brake fluid for front brake Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations. Info Never user DOT 5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. 100180-10 (690 Supermoto) – Remove screws . – Remove cover  with membrane . – Add brake fluid to level . Requirement Measurement of  5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 231) – Check parts for damage and wear. Replace damaged or worn parts. – Position the cover with the membrane. Mount and tighten screws. Info Clean up overflowed or spilt brake fluid immediately with water.
13/BRAKE SYSTEM 76 100181-10 (690 Supermoto R) – Loosen the screws. – Remove cover  with membrane . – Add brake fluid to the MAX level. Brake fluid DOT 4 / DOT 5.1 ( p. 231) – Check parts for damage and wear. Replace damaged or worn parts. – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 12.5Checking the rear brake linings Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. 100139-10 – Check the brake linings for minimum thickness . Minimum thickness  ≥ 1 mm (≥ 0.04 in) » If the minimum thickness is less than specified: – Change the rear brake linings. 12.6Checking free play of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications. 100182-10 – Disconnect spring . – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play . Requirement Free play at foot brake lever 3… 5 mm (0.12… 0.2 in) » If the free travel does not meet specifications: – Have the free travel corrected in an authorized KTM workshop. – Reconnect spring .
13/BRAKE SYSTEM 77 12.7Checking rear brake fluid level Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 100138-10 – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking : – Top up the brake fluid of the rear brake. ( p. 77) 12.8Topping up brake fluid of rear brake Warning Danger of accidents Brake system failure. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! 100176-10 – Stand the vehicle upright. – Remove screw cover  with membrane . – Top up the brake fluid to MAX level. Brake fluid DOT 4 / DOT 5.1 ( p. 231) – Check parts for damage and wear. Replace damaged or worn parts. – Refit screw with membrane. Info Clean up overflowed or spilt brake fluid immediately with water.
14/LIGHT SYSTEM, INSTRUMENTS 78 13.1Setting kilometers or miles Info If you change the unit, the ODO value is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is standing. 700120-01 – Switch on the ignition by turning the ignition key to the position (690 SUPER- MOTO R EU/AUS/UK, 690 Supermoto) (690 Supermoto R USA). – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button pressed until the display mode changes from Km/h to Mph or from Mph to Km/h. Requirement Activation duration of MODE button 10 s 13.2Setting the clock Condition The motorcycle is standing. 700115-10 – Switch on the ignition by turning the ignition key to the position (690 SUPER- MOTO R EU/AUS/UK, 690 Supermoto) (690 Supermoto R USA). – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time begins to flash. – Press the MODE button to adjust the hour. – Press the SET button to adjust the minute. – Keep the MODE button and the SET button pressed simultaneously. The time is set. 13.3Combination instrument - setting/resetting TRIP 1 display Info The tripmaster TRIP 1 operates constantly and counts up to 999.9. You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0. 700121-01 – Switch on the ignition by turning the ignition key to the position (690 SUPER- MOTO R EU/AUS/UK, 690 Supermoto) (690 Supermoto R USA). – Press the MODE button several times until the TRIP 1 display mode is active. – Keep the SET button pressed. The TRIP 1 display is at 0.0.
14/LIGHT SYSTEM, INSTRUMENTS 79 13.4Combination instrument - setting/resetting TRIP 2 display Info The tripmaster TRIP 2 operates constantly and counts up to 999.9. You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0. 700122-01 – Switch on the ignition by turning the ignition key to the position (690 SUPER- MOTO R EU/AUS/UK, 690 Supermoto) (690 Supermoto R USA). – Press the MODE button several times until the TRIP 2 display mode is active. – Keep the SET button pressed. The TRIP 2 display is at 0.0. 13.5Checking headlamp setting B A 100159-10 – On a light-colored wall with a horizontal area in front of it, make a mark as high as the center of the low beam headlight. – Make another mark at a distance of  under the first mark. Requirement Distance  5 cm (2 in) – Stand the motorcycle at a distance of  in front of the wall and switch on the low beam. Requirement Distance  5 m (16 ft) – Check the headlamp setting. The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver. » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 79) 13.6Adjusting the headlight range – Check the headlamp setting. ( p. 79) 100158-10 – Use a screwdriver (see illustration) to adjust the headlight range. Requirement The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking headlight adjustment). Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range. If you have a payload, you may have to correct the headlight range. 13.7Removing headlight mask with headlight 100155-10 – Remove the 4 screws  and carefully take off the headlight mask.
14/LIGHT SYSTEM, INSTRUMENTS 80 100156-10 – Pull the bulb holder of the parking light  out of the headlight housing. – Pull the plug-in connector  off the headlight. – Place the headlight mask to one side. 13.8Refitting the headlight mask with the headlight 100156-11 – Connect the plug-in connector  to the headlight. – Insert the bulb holder of the parking light  into the headlight housing. 100155-11 – Position the headlight mask. Mount and tighten screws . Requirement Screw, headlight mask M6 5 Nm (3.7 lbf ft) – Check lighting function. 13.9Changing the parking lamp Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector. – Switch off all power-consuming components and switch off the engine. – Remove the headlight mask with the headlight. ( p. 79) 100161-10 – Pull the parking light bulb  out of the holder. – Check parts for damage and wear. Replace damaged or worn parts. – Insert a new parking light bulb in the holder. Parking light (W2,1x9,5d) ( p. 208) – Refit the headlight mask with the headlight. ( p. 80)
14/LIGHT SYSTEM, INSTRUMENTS 81 13.10Changing headlight bulb Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector. – Switch off all power-consuming components and switch off the engine. – Remove the headlight mask with the headlight. ( p. 79) 100157-10 – Take the rubber cap off the headlight lamp. – Turn the bulb holder  about 30° counterclockwise and remove it. – Take the headlight bulb out of the headlight housing. – Check parts for damage and wear. Replace damaged or worn parts. – Insert a new headlight bulb into the headlight housing. Headlight (H4/P43t) ( p. 208) Info Insert the headlight bulb so that the bayonet lugs  latch into the slots . – Position the bulb holder and turn it clockwise as far as it will go. – Replace the rubber cap. – Refit the headlight mask with the headlight. ( p. 80) 13.11Changing flasher bulb Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector. 100160-10 – Remove the screw on the rear of the flasher housing. – Carefully swing the diffuser  forwards and remove it. – Press the flasher bulb carefully into the holder, turn it about 30° counterclockwise and remove it from the holder. Info Do not touch the reflector with your fingers and try to avoid contact will oil or grease. – Check parts for damage and wear. Replace damaged or worn parts. – Press the new flasher bulb carefully into the holder and turn it clockwise as far as it will go. Flasher light (BAU15s) ( p. 208) – Position the diffuser. – Insert the screw and turn it first counterclockwise until you feel it click into the thread. Tighten the screw. – Check the flasher function.
30/ENGINE 82 14.1Removing the engine – Jack up the rear of the motorcycle. ( p. 9) – Remove the seat. ( p. 58) – Dismount the fuel tank. ( p. 58) – Disconnect the negative (minus) cable of the battery. ( p. 70) – Drain the coolant. ( p. 145) – Remove the exhaust manifold. ( p. 55) 300177-12 – Loosen the spring-loaded band-type clamps. Detach radiator hoses. Pliers for spring-loaded band-type clamp (60029057100) ( p. 237) 300178-12 – Remove the radiator bracket nuts. – Swing the radiator forwards. 300179-10 – Remove screws . – Take off the engine sprocket cover. 300180-10 – Remove screws . – Take off the chain securing guide. – Remove screw . – Take off the shift lever. 300181-10 – Have an assistant operate the rear brake. – Bend up the lock washer. – Remove the nut of the engine sprocket with the lock washer. – Remove screw .
30/ENGINE 83 300183-10 – Loosen the nut  of the wheel spindle. – Remove nut . Remove chain adjuster. – Pull out the wheel spindle only far enough to allow the rear wheel to be pushed for- ward. – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. 300182-10 – Take off the engine sprocket. – Take off the clutch slave cylinder and hang it to the side. Info Do not bend the clutch line. Do not operate the clutch when the clutch slave cylinder is removed. – Take off the clutch push rod. 300184-10 – Unscrew the electrical connection  from the starter motor. – Unscrew ground wire  from the starter motor. 300185-10 – Remove the screw  of the footbrake pedal. – Detach and remove the spring. – Remove the footbrake pedal. 300186-10 – Loosen the hose clip . – Pull the throttle valve body to the rear out of the rubber sleeve. 300187-10 – Disconnect the plug connectors  from the gear position sensor, the ignition pulse generator and the generator. – Remove the cable binders and release the cables.
30/ENGINE 84 300188-10 – Pull of the spark plug connector. – Unplug the connector of the coolant temperature sensor . 300189-10 – Loosen the spring-loaded band-type clamps  from the breather, SLS and oil return feed with the special tool. Pliers for spring-loaded band-type clamp (60029057100) ( p. 237) – Pull of the hoses. 300190-10 – Remove screws . Take off the connecting bracket. 300191-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 241) 300192-10 – Remove the nut  of the lower engine bracket. Remove screw. 300193-10 – Remove the cover  on both sides.
30/ENGINE 85 300194-10 – Remove the nut  of the swingarm pivot. – Remove the swingarm pivot. – Loosen the adjusting rings  using the special tool. Mortise key (75029034000) ( p. 239) Info Fix the link fork in the frame using a suitable tool. 300195-10 – Lower the engine. Info You should have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage. 14.2Installing the engine – Raise the engine onto the special tool and fix it. Floor jack attachment (75029055000) ( p. 241) 300197-10 – Position the engine in the frame. – Mount the swingarm pivot. – Hand-tighten the adjusting rings with the special tool . Mortise key (75029034000) ( p. 239) 300233-10 – Install the screw and nut  of the lower engine bracket, but do not tighten them yet. 300191-10 – Remove the floor jack with the special tool. Floor jack attachment (75029055000) ( p. 241)
30/ENGINE 86 300190-11 – Position the connecting bracket. – Mount and tighten screws . Requirement Screw, linkage bracket, front engine bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™ – Mount and tighten screw . Requirement Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™ – Tighten the lower engine bracket. Requirement Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™ 300196-11 – Tighten the adjusting rings with the special tool. Requirement Adjusting ring of swingarm bearing M24x1.5 25 Nm (18.4 lbf ft) – Install and tighten the nuts  of the swingarm pivot on both sides. Requirement Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) 300193-11 – Install the covers of the swingarm pivot on both sides. 300189-11 – Position the hoses of the engine vent, the SLS, and the oil return feed. Mount the spring-loaded band-type clamps using the special tool. Pliers for spring-loaded band-type clamp (60029057100) ( p. 237) 300188-11 – Attach the spark plug connector. – Plug in the connector of coolant temperature sensor .
30/ENGINE 87 300187-11 – Connect the plug connectors  of the gear position sensor, the ignition pulse gen- erator, and the generator. 300186-11 – Slide the throttle valve body into the rubber sleeves. – Position and tighten the hose clamp . 300185-11 – Position the footbrake pedal and install it with the spring. – Mount and tighten screw  with the nut. Requirement Screw, foot brake pedal M10 25 Nm (18.4 lbf ft) 300184-11 – Position the electrical connection  on the starter motor. Mount and tighten screw. Requirement Remaining screws, chassis M5 4 Nm (3 lbf ft) – Position the ground wire on the starter motor. Mount and tighten screw . Requirement Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™ 300182-10 – Insert the clutch push rod. – Position the clutch slave cylinder. – Mount the engine sprocket with the chain. 300183-11 – Position the rear wheel. – Install the wheel spindle, the chain adjusters, and the nut. – Push the rear wheel forward so that the chain adjusters are on the tensioning screws, and tighten the nut . Requirement Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)
30/ENGINE 88 300181-11 – Have an assistant operate the rear brake. – Position new lock washer. Mount and tighten the nut. Requirement Nut, engine sprocket M20x1.5 60 Nm (44.3 lbf ft) Loctite® 243™ – Secure the nut with the lock washer. – Mount the screw  but do not tighten it yet. Requirement Screw, clutch slave cylin- der M6x20 10 Nm (7.4 lbf ft) Loctite® 243™ 300180-11 – Position the chain securing guide. – Mount and tighten screws . Requirement Screw, clutch slave cylinder M6x35 10 Nm (7.4 lbf ft) – Tighten screw . – Position the shift lever. – Mount and tighten screw  with the washers. Requirement Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 222 300179-11 – Position the rear sprocket cover. – Mount and tighten screws . Requirement Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 300178-13 – Position the radiator. Mount and tighten screws . Requirement Lower radiator bracket nut M6 5 Nm (3.7 lbf ft) 300177-13 – Position the radiator hoses. Install the spring-loaded band-type clamps . Pliers for spring-loaded band-type clamp (60029057100) ( p. 237) – Install the exhaust manifold. ( p. 56) – Reconnect the negative (minus) cable of the battery. ( p. 71)
30/ENGINE 89 300802-11 – Remove the oil filler plug with O-ring  from the clutch cover and fill up with engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 231) Alternative engine oil Engine oil (SAE 10W/50) ( p. 231) – Install and tighten the oil filler plug with O-ring . – Fill/aerate the cooling system. ( p. 145) – Install the fuel tank. ( p. 59) – Taking rear from work stand. ( p. 10) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p. 149) – Check the coolant level. ( p. 147)
30/DISASSEMBLING THE ENGINE 90 15.1Clamping engine into engine work stand 300144-10 – Mount special tool  on engine work stand . Engine work stand (61229001000) ( p. 237) Support for engine work stand (75012001060) ( p. 238) Holder for engine work stand (75012001070) ( p. 238) – Mount the engine on special tool . Info Have an assistant help you or use a crane. 15.2Draining engine oil 300002-10 – Remove the oil drain plug  with the magnet and seal ring. – Remove the plug  with the oil screen and O-rings. 300161-10 – Remove the plug  with the oil screen  and O-rings. – Completely drain the engine oil. 15.3Removing starter motor 300001-01 – Remove screws . Take off the starter motor. 15.4Removing valve cover 300003-10 – Remove screws . Take off the valve cover with the valve cover seal.
30/DISASSEMBLING THE ENGINE 91 15.5Removing generator cover 300004-10 – Remove screws . Take off the generator cover. – Remove dowels. 15.6Removing spacing sleeve 300153-10 – Remove the spacing sleeve  of the countershaft. 15.7Removing gear position sensor 300006-10 – Remove screws. Remove the gear position sensor . 300007-10 – Remove O-ring . – Remove contact pin  and the contact springs . 15.8Removing oil filter 300009-10 – Remove screws. Remove the oil filter cover  with the O-ring. – Pull the oil filter element  out of the oil filter case. Circlip pliers reverse (51012011000) ( p. 235)
30/DISASSEMBLING THE ENGINE 92 300011-10 – Remove screws. Remove the oil filter cover  with the O-ring. – Pull the oil filter element  out of the oil filter case. Circlip pliers reverse (51012011000) ( p. 235) 15.9Removing thermostat 300010-10 – Remove screws. Take off the thermostat case  with the radiator hose. – Pull out the thermostat . 15.10Setting engine to ignition top dead center 300023-10 – Turn the crankshaft counterclockwise until markings  of the camshafts are flush with the marks of the camshaft support plate. 300024-10 – Remove screw . Info Look through the hole to check that the position hole of the balancer shaft is visible. – Screw in special tool . Engine blocking screw (77329010000) ( p. 242) 15.11Removing water pump wheel 300012-10 – Remove screws . Take off the water pump cover.
30/DISASSEMBLING THE ENGINE 93 300013-10 – Remove screw . Take off the water pump wheel . – Take off the water pump cover seal. Info Do not lose the centering pins. 300014-10 – Remove the shaped washer . 15.12Removing clutch cover 300015-10 – Remove screws . Take off the clutch cover. – Take off the dowels. Remove the clutch cover seal. 15.13Removing spacer and spring 300154-10 – Remove the spacer  and spring  of the shift shaft. 15.14Removing spark plug 300016-10 – Remove the spark plug using the special tool . Spark plug wrench (75029172000) ( p. 242)
30/DISASSEMBLING THE ENGINE 94 15.15Removing timing chain tensioner 300017-10 – Remove screw . Take off the seal ring. – Pull out timing chain tensioner . 15.16Removing camshafts 300019-10 – Remove screw . Take off the camshaft support plate . 300020-10 – Pull the camshaft out of the bearing seats. Take the timing chain off the camshaft gear. Remove the camshaft. 15.17Removing cylinder head 300029-10 – Remove screws . – Alternately loosen screws  and remove them. – Take off the cylinder head. 15.18Removing piston 300030-10 – Take off the cylinder head gasket . – Remove screw . – Push the cylinder upward. Info Push the cylinder upward only far enough to allow removal of the piston pin. Pay attention to the whereabouts of the two grooved pins.
30/DISASSEMBLING THE ENGINE 95 300031-10 – Remove piston pin retainer . – Remove the piston pin. – Take off the cylinder with the piston. – Push the piston upward out of the cylinder. Info If no other work is required on the cylinder and the piston, you can leave the piston in the cylinder. – Take off the cylinder base gasket. Info Pay attention to the whereabouts of the two grooved pins. 15.19Removing rotor 300044-10 – Remove special tool . Engine blocking screw (77329010000) ( p. 242) 300040-10 – Use the special tool to hold the rotor tight. Holding spanner (75029091000) ( p. 242) – Loosen the nut  of the rotor and remove it with the tab washer. Info The crankshaft must not be blocked. 300041-10 – Install the special tool  on the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Extractor (58429009000) ( p. 235) – Remove special tool. 15.20Removing timing chain rails 300045-10 – Remove screws . – Pull the timing chain guide rails  out of the timing chain securing guide . Info The support bushing is plugged through the timing chain guide rails into the timing chain securing guide. – Take out the timing chain guide rails upwards through the chain shaft.
30/DISASSEMBLING THE ENGINE 96 300046-10 – Hold the timing chain securing guide tight and pull the timing chain tensioning rail  out of the timing chain securing guide. – Take out the timing chain tensioning rail upwards through the chain shaft. – Remove the timing chain securing guide . 15.21Removing timing chain and timing chain sprocket 300148-10 – Unthread the timing chain. Info Mark the direction of travel. – Take off the lock ring . 300149-10 – Pull of the timing chain sprocket with the special tool . Extractor (59029033000) ( p. 236) 15.22Removing ignition pulse generator 300151-10 – Remove the screws of ignition pulse generator . – Pull cable support sleeve  out of the engine case. Take off the ignition pulse gen- erator. 15.23Removing clutch cage 300051-10 – Compress the antihopping clutch with the special tool . Assembly screws (75029033000) ( p. 239) Info Apply the special tool with the hand only, do not use another tool.
30/DISASSEMBLING THE ENGINE 97 300052-10 – Loosen the screws  diagonally and remove them with their spring retainers and clutch springs. – Remove the pressure cap . 300053-10 – Remove the pressure piece . – Bend up the lock washer . 300054-10 – Hold the clutch cage using the special tool and remove the nut  of the inner clutch hub. Gear segment (75029081000) ( p. 241) Info Make sure that the crankshaft is not blocked. – Remove the nut  of the primary gear. Info Left-handed thread! 300055-10 – Take off the stepped washer and remove the half-washers . – Take off the clutch cage. 300056-10 – Remove needle bearing  and supporting plate .
30/DISASSEMBLING THE ENGINE 98 15.24Removing primary gear 300062-10 – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p. 242) – Screw the special tool  on to the primary gear . Extractor (75029021000) ( p. 238) – Hold it using the special tool and pull off the primary gear by turning the screw in. – Remove the special tools. 15.25Removing starter drive 300064-10 – Remove the lock ring of the starter idler gear  and the torque limiter . – Take off the starter idler gear  with the washers. – Remove the torque limiter  with the washers and needle bearing. 300065-10 – Take off the free-whell gear . – Remove the woodruff key  and both needle bearings . 15.26Removing shift shaft 300066-10 – Push sliding plate  away from the shift drum locating . Remove shift shaft  with the washer. 15.27Removing shift drum locating 300067-10 – Remove screw . – Press locking lever  away from shift drum locating  and take off the shift drum locating. – Release the locking lever.