690 SUPERMOTO ORANGE EU 2008

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1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF9726H0EN ENGLISH

3 INDEX FRONT FORK, TRIPLE CLAMP FRONT FORK DISSASEMBLED HANDLEBAR, CONTROLS FRAME 4x 5x 6x 7x SIDE / CENTER STAND MONOSHOCK PRO LEVER LINKING SWING ARM 9x 10x 11x 12x EXHAUST SYSTEM AIR FILTER TANK, SEAT, COVER FUEL PUMP 13x 14x 15x 16x 1

4 INDEX MASK, FENDERS DECAL FRONT WHEEL REAR WHEEL 17x 19x 20x 21x WIRING HARNESS BATTERY HAND BRAKE CYLINDER REAR BRAKE CONTROL 22x 23x 24x 25x BRAKE CALIPER FRONT BRAKE CALIPER REAR LIGHTING SYSTEM INSTRUMENTS / LOCK SYSTEM 26x 27x 28x 29x 2

5 INDEX SPECIAL TOOLS ACCESSORIES KIT 30x 31x x x x x x x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 3

6 FRONT FORK, TRIPLE CLAMP 1* 14187D07 FORK WP USD 48MM SM AH SCREW DIN6912-M10X60 2 7* HH COLLAR SCREW M8X30 TX AH SCREW DIN0912-M 8X30 4 9* HH COLLAR SCREW M5X20 TX SELF LOCKING NUT DIN0985-M CLAMP BRAKE HOSE S BOTTOM TRIPLE CLAMP CPL FORK TUBE LC8 ADV S TOP TRIPLE CLAMP 54MM STEER.HEAD SCREW M20X1,5 WS= S HANDLEBAR CLAMP 28MM S HANDLEBAR SUPPORT 28MM WASHER 10,5X32X RUBBER BUSHING SELF LOCK.NUT DIN0982-M10 HIGH SPACER TUBE 10,2X12X TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP STEERING HEAD COVER BUSHING MUD FLAP AH SCREW DIN6912 M6X SPLASH PROTECTOR BLACK MATT / C * NEW PART X AS REQUIRED 4

7 FRONT FORK DISSASEMBLED S1 AXLE CLAMP R/S CPL S1 AXLE CLAMP L/S CPL S SPRING 5,2N/MM L=415 D=5, COPPER WASHER 12X16X1, SPACER 42X26,5X2, SPACER 42X26,5X SPACER 42X26,5X SPACER 42X26,5X1, S SCREW CAP M51X1,5 CPL S1 CARTRIDGE CPl OUTER TUBE L=500MM D=54/ R14011 REPAIR-KIT GASKET S1 FORK OIL SAE5 5L T511 SILICONE GREASE F. DUST STRI DU-BUSH D47XD49X20DDL DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB DUST CAP D=48 58,4X11, / C * NEW PART X AS REQUIRED 5

8 HANDLEBAR, CONTROLS HANDLEBAR D=28MM VIBRATIONS ABSORBER AH SCREW DIN0912-M 6X THROTTLE GRIP CPL GRIPP SET THROTTLE CABLE SUPPORT FOR MIRROR LC4 ' REVIEW MIRROR L/S REVIEW MIRROR R/S MASTER CYLINDER CPL. 11MM CLAMP MIRROR WITH CLAMP 1 12* HH COLLAR SCREW M6X20 TX FLAT HEAD SCREW DIN0965-M 4X COVER FOR HYDR. CLUTCH ' RUBBER FOR RESERVOIR ' REP.SET PISTON 11MM PROTECT.CAP FOR LEVER PERCH' SPRING FOR CLUTCH LEVER CLUTCH LEVER LONG CPL LEVER SCREW CPL ' CLUTCH PIPE SM OIL FOR HYD. CLUTCH 75ML CLUTCH SWITCH LIGHT SWITCH START-STOP SWITCH AD LC / C * NEW PART X AS REQUIRED 6

9 FRAME 1* FRAME "EE08" BLACK MATT CONNECTION BRACKET ENG. L/S CONNECTION BRACKET ENG. R/S AH SCREW DIN912 M8X SPECIAL SCREW M10X115 ISK SCREW COLLAR NUT M10 WS= CHAIN SLIDING PIECE BUSHING 8,2X10X * HH COLLAR SCREW M8X30 TX WASHER DIN0125-A 8, S FLAT HEAD SCREW M. ISA45 M8X PLUG SFL SUB FRAME PLATINUM FL.HEAD SCREW M10X1,25 L= S FOOTREST BRACKET REAR L/S S FOOTREST BRACKET REAR R/S S FOOTREST CARRIER L/S S FOOTREST CARRIER R/S AH SCREW DIN0912-M 8X FLAT HEAD SCREW DIN7991-M 8X AH SCREW DIN912 M8x FOOTREST CPL. L/S REAR FOOTREST CPL. R/S REAR BOLT FOR FOOTREST REAR TAB WASHER DIN6799-RS 6, ENGAGE PANEL FOOTREST R/S ENGAGE PANEL FOOTREST L/S FOOTREST L/S+R/S CPL FOOT PED L/S SILVER FOOT PED R/S SILVER BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL FOOTREST RUBBER FRONT L/S / C * NEW PART X AS REQUIRED 7

10 FRAME FOOTREST RUBBER FRONT R/S CLOSING PANEL FRONT L/S R/S SELF LOCKING NUT DIN0985-M / C * NEW PART X AS REQUIRED 8

11 SIDE / CENTER STAND SIDE STAND L=293MM SPRING L=116 MM SCREW F. SIDE STAND M10X31, SPE. SCREW SIDE STAND SPRING MAGNET HOLDER * HH COLLAR SCREW M6X12 TX SIDESTAND BRACKET FORGING SPECIAL SCREW M6X16 WS= * HH COLLAR SCREW M8X16 TX SIDE STAND SENSOR CYL.HEAD SCREW DIN0084-M 4X8 A / C * NEW PART X AS REQUIRED 9

12 MONOSHOCK 1* 15189D07 MONOSHOCK SM SCREW M 10 L=53MM S SPRING (61) D=11, COUNTERNUT ADJUSTING NUT SPRING RETAINER H=15 D= R15005 REPAIR KIT GASKET R15006 REPAIR KIT BEARINGS S1 SHOCK ABSORBER FLUID 5 LT ' S1 MONOSHOCK LOWER PART CPL S MONOSHOCK CASE TOP SCREW M5 C.K. RVS SEAL D5,21XD8,38X1, CIRCLIP 49X1, / C * NEW PART X AS REQUIRED 10

13 PRO LEVER LINKING NEEDLE BUSH HK BUSHING SLEEVE 15 X 20 X STEEL WASHER 15,2X19X0, SHAFT SEAL RING 25X32X SPAC.F.SHAFT SEALRING 15X25X SPACER SLEEVE 15X20X BEARING BUSHING SETTING LEVER CPL INTERMEDIATE LEVER CPL BOLT CPL BOLT KPL SELF LOCKING NUT M14X1,5 WS= PLASTIC CAP SFL / C * NEW PART X AS REQUIRED 11

14 SWING ARM SWING SM CPL BUCKET F. SHAFT SEAL RING SHAFT SEAL RING 25X32X BEARING SLEEVE 17X22X38, NEEDLE BEARING HK2212V STOP DISK 22,2X31,7X CHAIN SLIDING PROTECTION BUCKET 4 9* HH COLLAR SCREW M6X8 TX RET. CLAMP F. BRAKE HOSE BLACK SPECIAL SCREW M 5,0X CHAIN GUARD SPECIAL SCREW T60 6X30 WS= BUSHING MUD FLAP AH SCREW DIN6912 M6X MUD FLAP SWING ARM BOLT L=272MM SELF LOCK.NUT M16X1,5 WS= WASHER ADJUSTING RING M24X1, PLASTIC CAP / C * NEW PART X AS REQUIRED 12

15 EXHAUST SYSTEM EXHAUST MANIFOLD EXHAUST GASKET SPACER BUSH. 8,5X15X7, SELF LOCKING NUT M 8 CU LAMBDA SENSOR BRACKET CPL * HH COLLAR SCREW M8X16 TX SLEEVE SILENCER SUPPORT RUBBER SILENCER SUPPORT * BRACKET FOR MANIFOLD HH COLLAR SCREW M8X30 TX EXHAUST BRACKET RUBBER BLACK EXHAUST GASKET SILENCER L/S LC SILENCER R/S LC CLAMP MAIN SILENCER CPL BUSHING 8MM F. EXHAUST SUPPORT WASHER DIN9021-A 8, THERMAL SHIELD L/S THERMAL SHIELD R/S SCREW TORX M5X TOOTH LOCK WASHER DIN6797-J DAMP. COMPON. SILICONE GREY / C * NEW PART X AS REQUIRED 13

16 AIR FILTER AIRBOX UPPER-PART FILTERBOX SUPPORT CROSS INTAKE TRUMPET GASKET FILTER BOX COVER FILTER BOX COVER * COLLAR SCREW M5X12 ISA30 2 7* HH COLLAR SCREW M5X20 TX SPECIAL SCREW T60 6X30 WS= SCREW TORX M5X METAMOL FOR AIR FILTER BOX HOSE SLS AIRFILTERBOX HOSE OIL SEPARATOR - BREATH HOSE CLAMP 50-70MM AIRBOX LOWER-PART INTAKE SNORKEL SCREW FOR PLASTIC 50X PLUG SFL AH SCREW DIN0912-M 5X GASKET FILTER BOX FILTER FRAME AIRFILTER AIRBOX MIDDLE-PART OIL SEPARATOR FOAM CABLE TIE 200/3,6MM BLACK / C * NEW PART X AS REQUIRED 14

17 TANK, SEAT, COVER A FUEL TANK BLACK CPL TANK PLUG KEY BLANK LC4/DUKE/LC HOSE NBR 5,4X9,4 PER METER x ONLY FOR USA SCREW FOR SEAT M6X11,5/ AH SCREW DIN0912-M 8X BEARING BUSHING OUTSIDE TANK RUBBER BUSHING RUBBER BUFFER SPECIAL SCREW M GAS-LEVEL SENSOR ADV AH SCREW DIN0912-M 5X * HH COLLAR SCREW M6X12 TX FUEL COCK CPL. SMALL RALLYE' O-RING 11X1,8 NBR * FUEL HOSE WITH CLUTCH 1 18* FUEL HOSE WITH CLUTCH O-RING VITON F. PLUG CPC SPOILER L/S ORANGE SPOILER R/S ORANGE * HH COLLAR SCREW M6X10 TX SPECIAL WASHER D=16,5MM AH SCREW DIN6912 M6X VARIABLE ONE-EAR CLAMP 14,2 MM SEAT BLACK SEAT COVER LOW SEAT LOCK OVAL HEAD SCREW DIN0966-M 5X * HH COLLAR SCREW M5x12 TX SEAT RUBBER 6 MM SEAT RUBBER 10 MM RUBBER SLEEVE F.SEAT LOCK ' / C * NEW PART X AS REQUIRED 15

18 FUEL PUMP SEALINGS KIT FILTER KIT FUEL PUMP WITH FLANGE CPL PRESSURE REGULATOR CPL HYDRAULIC CONNECTOR CPL VARIABLE ONE-EAR CLAMP 15,3MM 4 8* FUEL HOSE WITH CLUTCH O-RING VITON F. PLUG CPC * FUEL HOSE WITH CLUTCH 1 20* HH COLLAR SCREW M5X16 TX / C * NEW PART X AS REQUIRED 16

19 MASK, FENDERS HEAD LIGHT MASK ORANGE RANGE CHANGE METAL NUT M RUBBER SLEEVE D=8MM OPEN COLLAR BUSHING 6,1X8,1X14X * HH COLLAR SCREW M6X20 TX SIDE REFLECTOR YELLOW 03 2 ONLY FOR USA+AUS+UK REAR FENDER BLACK MATT SIDE COVER L/S ORANGE SIDE COVER R/S ORANGE RANGE CHANGE METAL NUT M WASHER REAR-UT D=14MM SCREW M5X14 TORX EJOT PT SCREW K60X20 WS= STORAGE COMPARTMENT RUBBER L=145MM MUD FLAP BUCKET 2 22* HH COLLAR SCREW M6X8 TX HAND GRIP L/S HAND GRIP R/S SCREW FOR PLASTIC 50X FLAT HEAD SCREW ISO10642 M8X SPACER SUB FRAME FRONT L/S SPACER SUB FRAME FRONT R/S SPACER SUB FRAME REAR L/S SPACER SUB FRAME REAR R/S NUMBER PLATE CARRIER TOP NUMBER PLATE CARRIER WASHER DIN9021-A 6,4 3 43* HH COLLAR SCREW M6X35 TX * HH COLLAR SCREW M6X20 TX EJOT PT SCREW K60X20 WS= LICENCE FITTING * HH COLLAR SCREW M6X15 TX WASHER DIN9021-A 6, / C * NEW PART X AS REQUIRED 17

20 MASK, FENDERS SELF LOCK. NUT DIN0985-M OVAL HEAD SCREW DIN0966-M 5X WASHER 6MM WASHER DIN0125-A 5, SELF LOCKING NUT DIN0985-M REFLECTOR RED LC4 ' BRACKET FOR REFLECTOR BRACKET SIDE REFLECTOR SIDE REFLECTOR RED REAR 2 ONLY FOR USA 64* SPREAD RIVET CPL. 6,2MM x / C * NEW PART X AS REQUIRED 18

21 DECAL DECAL SET 690 SM ORANGE / C * NEW PART X AS REQUIRED 19

22 FRONT WHEEL FRONT WHEEL CPL. 3,5X17" FRONT HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM SHAFT SEAL RING 35X47X7 TC SPACER BUSHING FRONT WHEEL RIM FRONT 3,5X17" BLACK SPOKE M4,5X172-15G 17" INOX 36 11* SPOKE NIPPLE M4,5X0,75 8X HOSE 3,5X17" RIM BAND 17" WHEEL SPINDLE FRONT D=26MM SPINDLE SCREW M24X1,5 WS= BRAKE DISC ADAPTOR BRAKE DISC FRONT 320MM SPECIAL SCREW M6X23 WS= / C * NEW PART X AS REQUIRED 20

23 REAR WHEEL REAR WHEEL CPL. 5X17" REAR HUB CPL BEARING SPACER TUBE L=106MM GR.BALL BEAR RSHC3HMTF CIRCLIP DIN X SHAFT SEAL RING 30X52X SPACER BUSH. REAR WHEEL R/S SPACER RING RIM 5X17" BLACK SPOKE M5X199-16G 17" INOX SPOKE M5X188-27G 17" INOX SPOKE NIPPLE M5-TA (8X21MM) TUBE 17" RIM BAND 17" SPROCKET STEALTH 40T 07 x SPROCKET STEALTH 42T 07 x S COUNTER-SUNK SCREW ISA45 M8X SELF LOCKING NUT M SPROCKET SUPPORT CPL SPACER BUSH. SPROCKET SUPP NILOS RING 6006AV BALL BEARING 6006 DDU2CG23S6NM SPACER BUSH. SPR. SUPP. IN DAMPING RUBBER ' REAR BRAKE DISK D=240MM SPECIAL SCREW M6X13 WS= WHEEL SPINDLE REAR L=279MM CHAIN TENSIONER R/S LC COLLAR NUT WH. SPINDLE REAR HH COLLAR NUT M10X1,25 WS= SCREW M10X1,25X50 WS= CHAIN X-RING RIVET LINK RIVET LINK FOR / C * NEW PART X AS REQUIRED 21

24 WIRING HARNESS WIRING HARNESS BH SPARE CONNECTOR BH FUSE 10A 07 x FUSE 15A 07 x RUBBER CASING FOR FUSE BOX BRACKET FOR PLUGS * SCREW FOR PLASTIC K50X12 T20 3 8* HH COLLAR SCREW M6X10 TX DC HORN CLAMP RSGU 15/ AH SCREW DIN0912-M 5X CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x RUBBER CABLE TIE 75MM 03 x FLASHER UNIT BRACKET FOR FLASHER RELAISE DIODE S3H / C * NEW PART X AS REQUIRED 22

25 BATTERY STARTER CABLE BATTERY CABLE GROUND CABLE BRACKET RUBBER FOR BATTERY BATTERY 12V 8,6AH METAMOL FOR BATTERY BRACKET STARTER RELAY FUSE 30 A BATTERY BRACKET CPL RELAY CM1A-R-12V-H COLLAR SCREW M6X27 TX 2 12* VOLTAGE REGULATOR RUBBER GROMMET 20X15-M6X10 (1) 4 14* HH COLLAR SCREW M6X10 TX AH OVAL SCREW ISO 7380 M 6X AH SCREW DIN 912 M 5X POSITIVE POLE COVER CONTACT WASHER M6 VSV-K6 1 23* HH COLLAR SCREW M6X16 TX * HH COLLAR SCREW M6X10 TX HEXAGON NUT DIN0934-M / C * NEW PART X AS REQUIRED 23

26 HAND BRAKE CYLINDER HANDBRAKE CYL.DUKE ADJUST HAND BRAKE LEVER LOOSE ADJ COVERING CAP FOR LEVER SCREW RUBBER BOOT DUKE COVER BREMBO DUKE ' LEVER SCREW CPL BRAKE LIGHT SWITCH FRONT SM FLAT HEAD SCREW DIN0965-M 5X * HH COLLAR SCREW M6X20 TX CLAMP MIRROW M10X1, REPAIR KIT CPL. D=13MM BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 24

27 REAR BRAKE CONTROL FOOT BRAKE LEVER CPL STEP PLATE FOOT BRAKE LEVER SCREW TORX M5X BALL BEARING SKF RS LOCK RING DIN7993-B AH SCREW DIN6912 M10X COLLAR NUT M10 WS= SPRING FOOT BRAKE LEVER * S HH COLLAR SCREW M6X20 TX HEXAGON NUT DIN0934-M SWIVEL HEAD M6 FOOT BRAKE LEV PRESSURE ROD ALU 250 ' MAIN BRAKE CYLINDER ' BRAKE CYL. PROTECTOR "BREMBO" COLLAR BUSHING CABLE TIE 200/3,6MM BLACK CLAMP D=6/8MM, BLACK YDNAC CLAMP (9MM) HOSE FOR RESERVOIR 6X1,5 x BRAKE FLUID RESERVOIR ' * HH COLLAR SCREW M6X10 TX COPPER GASKET DIN X14X BRAKE HOSE REAR BRAKE LIGHT SWITCH REAR ' BRAKE FLUID DOT5.1 0,25L REPAIR KIT PISTON 13MM / C * NEW PART X AS REQUIRED 25

28 BRAKE CALIPER FRONT BRAKE CALIPER FRONT SPACER BUSH 10,1X20X7, AH-COLLAR SCREW M10X1,25X BRAKE PAD FR. HAWK HH RETAINING SPRING BREMBO ' BOLT WHITH CLIP ' BRAKE HOSE FRONT CPL BLEEDER SCREW CPL COPPER GASKET DIN X14X HOLLOW SCREW BLACK M10X1X / C * NEW PART X AS REQUIRED 26

29 BRAKE CALIPER REAR BRAKE CALIPER REAR RETAINING SPRING SET CUP SET SHORT BLEEDER SCREW WITH CAP BRAKE PISTON 32MM REPAIR KIT SEALING RINGS 32MM BRAKE PAD SET REAR SBS-S-40GF BOLT SET HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X BRAKE HOSE REAR / C * NEW PART X AS REQUIRED 27

30 LIGHTING SYSTEM HEAD LIGHT LC BULB H4 12V 60/55W (P43T) 1 3* RUBBER CAP FOR HEAD LIGHT SCREW FOR PLASTIC 50X FLASHER CPL.FRONT L/S REAR R/S FLASHER CPL.FRONT R/S REAR L/S FLASHER LENS L/S R/S TRANSP BULB 12V ORANGE (RY10W) WASHER 18x10,5x1, LOCK WASHER DIN6797-J10,5 ZI FLASHER NUT M10X1,25 WS HH COLLAR NUT M10X1,25 WS= REAR LIGHT LED * HH COLLAR SCREW M5x12 TX LICENSE PLATE ILLUMINATION * SCREW FOR PLASTIC K50X18 T BULB 12V 5W (W2,1X9,5D) PHIL WIRING HARNESS REAR / C * NEW PART X AS REQUIRED 28

31 INSTRUMENTS / LOCK SYSTEM SPEEDOMETER 07 1 REPROGRAMMABLE KM/H - MPH SPEEDOMETER SENSOR CLAMP 5/7 MM CYL.HEAD SCREW DIN0084-M 4X8 A RUBBER GROMMET 16X10,8X WASHER DIN9021-A 5,3 3 7* SCREW FOR PLASTIC K50X12 T LOCK SYSTEM IGNITION LOCK TAMPERPROOF SCREW F. IGN. LOCK KEY BLANK LC4/DUKE/LC SPEEDOMETER BRACKET COVER MASK BRACKET L/S MASK BRACKET R/S RANGE CHANGE METAL NUT M RUBBER SLEEVE D=8MM OPEN COLLAR BUSHING 6,1X8,1X14X * HH COLLAR SCREW M6X20 TX * HH COLLAR SCREW M6X15 TX * HH COLLAR SCREW M6X10 TX * METAMOLL 1 31* METAMOLL / C * NEW PART X AS REQUIRED 29

32 SPECIAL TOOLS VEHICLE STAND BRACKET FOR ASSEMBLING RACK SP. BROCKET SW.ARM BEARING ADJ ATTACHMENT SHUNTING JACK CPL STOP RUBBER M HEXAGON NUT DIN0934-M / C * NEW PART X AS REQUIRED 30

33 ACCESSORIES KIT WASHER DIN9021-A 6, HH COLLAR SCREW M6X15 TX WASHER DIN0125-A 5, OVAL HEAD SCREW DIN0966-M 5X SELF LOCKING NUT DIN0985-M SELF LOCK. NUT DIN0985-M DOCUMENTS BAG KTM BALLPOINT ORANGE WASHER 6MM SUPPORT FOR MIRROR LC4 ' REFLECTOR RED LC4 ' BRACKET FOR REFLECTOR FOOTREST L/S+R/S CPL LICENCE FITTING REVIEW MIRROR L/S REVIEW MIRROR R/S OWNERS MANUAL 690 LC4 SM * TOOL SET * GRIP ORANGE B&F 1 31* WRENCH SW=17/21/27/32 B&F 1 32* T-WRENCH WS=6/8/10 TX=45 B&F SCREW DRIVER L=105MM WRENCH WS=13/ SPARK PLUG WRENCH / C * NEW PART X AS REQUIRED 31

34 NOTICE

36 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CF9726H0EN* 3CF9726H0EN Art.Nr.: 3CF9726H0EN 12/2007

690 SUPERMOTO PRESTIGE AUS/UK 2007

690 SUPERMOTO PRESTIGE AUS/UK 2007 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF9760G5EN ENGLISH INDEX FRONT FORK DISSASEMBLED FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME 4x 5x 6x 7x SIDE / CENTER STAND MONOSHOCK PRO LEVER LINKING SWING