KTM 690 Duke 2009 Maintenance Schedule
The 2009 KTM 690 Duke maintenance schedule below covers the manufacturer's recommended service intervals for oil, valve clearance, general maintenance, spark plugs, coolant, air filter, brake fluid, tires, drive chain maintenance and battery. Intervals are shown in kilometres by default and can be switched to miles.
654ccEngine size
54Maintenance items
Official manufacturer manual
Sourced from KTM Official Manuals (this document covers model years 2008–2011): azwecdnepstoragewebsiteuploads.azureedge.net
Full schedule
| Task | Interval | Difficulty | Notes |
|---|---|---|---|
| Change engine oil and oil filter, clean oil screens. | Every 5,000 km (first at 1,000 km) · Every 12 months | Moderate | Change engine oil and oil filter, clean oil screens. |
| Check and adjust valve clearance. | Every 10,000 km · Every 24 months | Moderate | Inspect and adjust valve clearance. |
| Check engine mounting screws for tightness. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check engine mounting screws for tightness. |
| Replace spark plug. | Every 10,000 km · Replace every 10,000 km | Easy | Replace spark plug. |
| Check engine bolts accessible from outside for tightness. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check externally accessible engine bolts for tightness. |
| Check connection boots for cracks and leakage. | Every 10,000 km (first at 1,000 km) · Every 24 months | Easy | Check connection boots for cracks and leakage. |
| Read out the error memory with a KTM diagnostic tool. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Read out error memory with KTM diagnostic tool. |
| Check fuel hoses, SLS hoses and vent hoses for damage, correct fitting and leaks. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check fuel/SLS/vent hoses for damage, fitting, and leaks. |
| Clean, check and grease the O-ring of the fuel hose connection. | Every 5,000 km · Every 12 months | Easy | Clean, check, and grease fuel hose connection O-ring. |
| Check the cable harness of the throttle valve body for damage and correct positioning. | Every 10,000 km (first at 1,000 km) · Every 24 months | Easy | Check throttle valve body cable harness for damage/positioning. |
| Check the cooling system for leakage. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check cooling system for leakage. |
| Check the antifreeze and coolant level. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check antifreeze and coolant level. |
| Check the functioning of the radiator fan. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check radiator fan operation. |
| Check the exhaust system for leaks and correct fitting and check that the exhaust holders are tight. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check exhaust system for leaks/fitting/holder tightness. |
| Check Bowden cables for damage, smooth operation, routing without sharp bends and setting. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check Bowden cables for damage/operation/routing/setting. |
| Check/correct the fluid level of the hydraulic clutch. | Every 5,000 km · Every 12 months | Easy | Check and correct hydraulic clutch fluid level. |
| Check air filter and change if necessary. Clean the air filter box. | Every 5,000 km · Every 12 months | Easy | Check air filter, replace if needed, clean air filter box. |
| Check cables for damage and routing without sharp bends. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check cables for damage and routing. |
| Check the headlamp setting. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check headlamp aim. |
| Check the functioning of the electrical equipment. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check electrical equipment function. |
| Check screws and nuts for tightness. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check screws and nuts for tightness. |
| Check the front brake linings. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check front brake pad/lining wear. |
| Check the rear brake linings. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check rear brake pad/lining wear. |
| Check the brake discs. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check brake discs for wear/damage. |
| Check the brake fluid level of the front brake. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check front brake fluid level. |
| Check the rear brake fluid level. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check rear brake fluid level. |
| Change brake fluid. | Every 24 months · Replace every 24 months | Moderate | Replace brake fluid. |
| Check brake lines for damage and leakage. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check brake lines for damage and leakage. |
| Check the free play of the foot brake lever. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check foot brake lever free play. |
| Check braking. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Road test braking performance. |
| Check screws and guide bolts of brake system for tightness. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check brake system screws/guide bolts for tightness. |
| Check shock absorber and fork for leakage and functioning. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check shock absorber and fork for leaks and function. |
| Clean dust boots of fork legs. | Every 5,000 km · Every 12 months | Easy | Clean fork leg dust boots. |
| Bleed fork legs. | Every 5,000 km (first at 1,000 km) · Every 12 months | Moderate | Bleed air from fork legs. |
| Check swingarm bearing. | Every 5,000 km (first at 1,000 km) · Every 12 months | Moderate | Check swingarm bearing for play. |
| Check play of steering head bearing. | Every 5,000 km (first at 1,000 km) · Every 12 months | Advanced | Check steering head bearing play. |
| Check all screws to see if they are tight. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | General screw tightness check. |
| Grease Pro-Lever deflector. | Every 24 months · Replace every 24 months | Easy | Grease Pro-Lever suspension linkage deflector. |
| Check rim run-out. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check wheel rim run-out. |
| Check the tire condition. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check tire tread condition. |
| Checking the tire air pressure. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check tire pressures. |
| Check the chain wear. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check drive chain wear. |
| Check rear sprocket / engine sprocket for tightness. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check rear and engine sprocket mounting tightness. |
| Check rear sprocket / engine sprocket for wear. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check rear and engine sprocket for wear. |
| Check the chain tension. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Check drive chain tension. |
| Clean the chain. | Every 5,000 km (first at 1,000 km) · Every 12 months | Easy | Clean and lubricate the drive chain. |
| Check wheel bearing for play. | Every 5,000 km · Every 12 months | Moderate | Check wheel bearings for play. |
| Checking the rear hub rubber dampers. | Every 5,000 km · Every 12 months | Easy | Check rear hub cush-drive rubber dampers. |
| Carry out a complete fork service. | Every 10,000 km · Every 24 months · Replace every 10,000 km · Replace every 24 months | Professional | Full fork internals service. |
| Carry out a complete shock absorber service. | Every 10,000 km · Every 24 months · Replace every 10,000 km · Replace every 24 months | Professional | Full shock absorber internals service. |
| Clean and grease steering head bearing and sealing elements. | Every 24 months · Replace every 24 months | Moderate | Clean and re-grease steering head bearing and seals. |
| Treat electric contacts with contact spray. | Every 12 months | Easy | Treat electrical contacts with contact spray. |
| Clean the battery terminals and treat them with contact grease. | Every 12 months | Easy | Clean battery terminals and apply contact grease. |
| Change coolant. | Every 24 months · Replace every 24 months | Moderate | Drain and replace engine coolant. |
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Easy: basic tools, straightforward Easy–Moderate: varies by task — somewhere between the two Moderate: some mechanical know-how helps Advanced: specialized tools/skill, still DIY-doable Expert: significant experience required Professional: dealer or shop recommended
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