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OWNER'S MANUAL
2010
690 ENDURO EU
690 ENDURO AUS/UK
690 Enduro R EU
690 Enduro R AUS/UK
Art. no. 3211511en

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  • Page 1 OWNER'S MANUAL 2010 690 ENDURO EU 690 ENDURO AUS/UK 690 Enduro R EU 690 Enduro R AUS/UK Art. no. 3211511en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you DEAR KTM CUSTOMER enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 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.
  • Page 5: Table Of Contents

    TABLE OF CONTENTS Combination instrument - TRIP F display (690 Enduro) ..27 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Combination instrument - coolant temperature indicator IMPORTANT INFORMATION ........... 8 (690 Enduro) ..............28 VIEW OF VEHICLE..............12 Combination instrument (690 Enduro R) ......28 View of vehicle, front left (example)........
  • Page 6 TABLE OF CONTENTS Loading the vehicle ............45 Loosening the fork protection..........76 RIDING INSTRUCTIONS ............47 Positioning the fork protection ........... 77 Checks before putting into operation ........47 Checking the steering head bearing play ......77 Starting ................48 Adjusting the play of the steering head bearing ....
  • Page 7 TABLE OF CONTENTS Checking the play in the throttle cable......148 Installing the rear wheel ..........110 Adjusting the play in the throttle cable ......149 Checking the rear hub rubber dampers ......112 Removing the engine guard ..........149 Checking the tire condition..........
  • Page 8 TABLE OF CONTENTS Capacity - fuel..............180 TECHNICAL DATA - FORK........... 181 690 Enduro ..............181 690 Enduro R ..............182 TECHNICAL DATA - SHOCK ABSORBER ......183 690 Enduro ..............183 690 Enduro R ..............184 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ..186 SUBSTANCES..............
  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
  • Page 10: Important Information

    Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth- erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 11: Spare Parts, Accessories

    Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 12 IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons.
  • Page 13 IMPORTANT INFORMATION 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 may lead to minor injuries if the appropriate measures are not taken.
  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 800087-10...
  • Page 15 VIEW OF VEHICLE Hand brake lever Clutch lever Handrail Filler cap Seat Front brake caliper Shift lever Engine number Side stand Footrest Seat release strap...
  • Page 16: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) 800086-10...
  • Page 17 VIEW OF VEHICLE Ignition/steering lock Rear mirror Light switch, turn signal switch, horn button Combination instrument Emergency OFF switch, electric starter button Throttle grip Chassis number Brake caliper, rear Passenger footrest Shock absorber, rebound damping Foot brake lever Level viewer, engine oil...
  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  100217-10 Type label Type label is located on the upper right frame tube below the seat.  100218-10...
  • Page 19: Key Number

    LOCATION OF SERIAL NUMBERS Key number 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. 100179-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.
  • Page 20: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  800072-10 Shock absorber part number The shock absorber part number is on the right of the shock absorber. ...
  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 100219-10 Hand brake lever The hand break lever is fitted on the right side of the handlebar. ...
  • Page 22: Light Switch

    CONTROLS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on.
  • Page 23: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar.  Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 100224-10 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.
  • Page 24: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar.  Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button 100226-10 Ignition/steering lock The ignition/steering lock...
  • Page 25: Combination Instrument (690 Enduro)

    CONTROLS Combination instrument (690 Enduro) The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. Function buttons  Tachometer  Indicator lights  Display  400832-10 Combination instrument - function buttons (690 Enduro) 5.10 You can change the display mode with the MODE button ...
  • Page 26: Combination Instrument - Tachometer (690 Enduro)

    CONTROLS Combination instrument - tachometer (690 Enduro) 5.11 The tachometer shows the engine speed in revolutions per minute.  The red marking shows the excess speed range of the engine.  400834-10 Combination instrument - indicator lamps (690 Enduro) 5.12 The indicator lamps offer additional information about the operating state of the motorcy- cle.
  • Page 27: Combination Instrument - Display (690 Enduro)

    CONTROLS FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. Battery warning lamp lights up red – Voltage in vehicle system too low. Combination instrument - display (690 Enduro) 5.13 When you switch on the ignition, all display segments light up for one second as a function test.
  • Page 28: Combination Instrument - Speedometer (690 Enduro)

    CONTROLS Combination instrument - speedometer (690 Enduro) 5.14 The speed is shown in kilometers per hour km/h or in miles per hour mph.  400838-10 Combination instrument - time (690 Enduro) 5.15 The time is shown in area of the display. ...
  • Page 29: Combination Instrument - Display Odo (690 Enduro)

    CONTROLS Combination instrument - display ODO (690 Enduro) 5.16 In the ODO display mode, the total distance traveled is shown in kilometers or miles. Info This value is retained, even if the battery is disconnected and/or the fuse blows. 400839-01 Combination instrument - TRIP F display (690 Enduro) 5.17 If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and...
  • Page 30: Combination Instrument - Coolant Temperature Indicator (690 Enduro)

    CONTROLS Combination instrument - coolant temperature indicator (690 Enduro) 5.18 The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up.
  • Page 31: Combination Instrument - Function Buttons (690 Enduro R)

    CONTROLS Combination instrument - function buttons (690 Enduro R) 5.20 You can change the display mode with the M button  Possible display modes are distance traveled (Odo), trip master 1 (Trip 1) and trip mas- ter 2 (Trip 2). Press the S button to reset the trip master 1 function (Trip 1) and trip master 2 function ...
  • Page 32: Combination Instrument - Display (690 Enduro R)

    CONTROLS FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. Combination instrument - display (690 Enduro R) 5.22 When you switch on the ignition, all display segments light up for a second as a function test.
  • Page 33: Combination Instrument - Speedometer (690 Enduro R)

    CONTROLS Combination instrument - speedometer (690 Enduro R) 5.23 The speed is shown in kilometers per hour km/h or in miles per hour mph.  800083-16 Combination instrument - time (690 Enduro R) 5.24 The time is shown in area of the display.
  • Page 34: Combination Instrument - Display Odo (690 Enduro R)

    CONTROLS Combination instrument - display ODO (690 Enduro R) 5.25 In the Odo display mode, the total distance traveled is shown in kilometers or miles. Info This value is retained, even if the battery is disconnected and/or the fuse blows. 800083-18 Combination instrument - TRIP F display (690 Enduro R) 5.26...
  • Page 35: Combination Instrument - Coolant Temperature Indicator (690 Enduro R)

    CONTROLS Combination instrument - coolant temperature indicator (690 Enduro R) 5.27 The temperature display consists of 8 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the tem- perature warning lamp lights up.
  • Page 36: Setting The Clock

    CONTROLS (690 Enduro) – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.
  • Page 37: Combination Instrument - Setting/Resetting Trip 1

    CONTROLS (690 Enduro) – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –...
  • Page 38: Combination Instrument - Setting/Resetting Trip 2

    CONTROLS (690 Enduro) – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 400840-01 (690 Enduro R) –...
  • Page 39 CONTROLS (690 Enduro) – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 (690 Enduro R) –...
  • Page 40: Opening Filler Cap

    CONTROLS Opening filler cap 5.32 – 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. 100227-10 Closing filler cap 5.33...
  • Page 41: Handrails

    CONTROLS Handrails 5.34 The handrails are used for moving the motorcycle around.  When you have a passenger, the passenger can hold on the handrails during the journey. 100229-10 Seat release 5.35 The seat can be released using strap  100230-10...
  • Page 42: Passenger Footrests

    CONTROLS Passenger footrests 5.36 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • 100231-01 Shift lever 5.37 The shift lever is mounted on the left side of the engine.
  • Page 43: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100212-10 Foot brake lever 5.38 Foot brake lever is located in front of the right footrest.  The rear brake is engaged with the foot brake lever. 100232-10...
  • Page 44: Side Stand

    CONTROLS Side stand 5.39 The side stand is coupled with the safety electric starter system - see the riding instruc-  tions. Possible states Side stand folded out – The vehicle can be supported on the side stand. The safety •...
  • Page 45: General Tips And Hints On Putting Into Operation

    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 characteristic 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. –...
  • Page 46: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
  • Page 47: Loading The Vehicle

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Loading the vehicle Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 48 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...
  • Page 49: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( p.
  • Page 50: Starting

    RIDING INSTRUCTIONS – Sit on the motorcycle and check the rear mirror setting. Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.
  • Page 51: Starting Up

    RIDING INSTRUCTIONS Info Do not press the electric starter button until the function test of the combination instrument is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 52 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury The passenger must be capable of sitting correctly on the passenger seat.
  • Page 53 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
  • Page 54 RIDING INSTRUCTIONS – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. (690 Enduro) – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the 6 forward gears in the figure.
  • Page 55: Braking

    Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
  • Page 56: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Failure of brake system. – If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake lever if you do not want to brake. Warning Danger of accidents Longer stopping distance due to higher overall weight.
  • Page 57 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components get very hot when the vehicle is in use. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them. Note Danger of damage The parked vehicle may roll away or fall over.
  • Page 58: Refueling

    RIDING INSTRUCTIONS – Swing the side stand forward with your foot as far as it will go and lean the vehicle on it. – Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to position and turning it to position To make the steering lock engage more easily, move the handlebar a little to the left and right.
  • Page 59 RIDING INSTRUCTIONS (690 Enduro) – Switch off engine. – Open the filler cap. ( p. 38) – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 20 mm (0.79 in)  Total fuel tank 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / capacity, approx.
  • Page 60 RIDING INSTRUCTIONS (690 Enduro R) – Switch off engine. – Open the filler cap. ( p. 38) – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 20 mm (0.79 in)  Total fuel tank 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / capacity, approx.
  • Page 61: Service Schedule

    Check that the electrical equipment is functioning correctly. • • • • • • • • Read out the fault memory using the KTM diagnostics tool. • • • • Change the engine oil and filter, clean the oil screens. p. 151) • •...
  • Page 62 Final check: Check the vehicle for roadworthiness and take a test ride. • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • • Make the service entry in KTM DEALER.NET and in the service record.
  • Page 63: Maintenance Work On Chassis And Engine

    MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up the motorcycle Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. (690 Enduro) – Jack up the motorcycle on the underride guard underneath the engine. The wheels must no longer touch the ground.
  • Page 64: Removing The Motorcycle From The Work Stand

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Remove the motorcycle from the work stand and rest it on its side stand. –...
  • Page 65 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove protection covers  – 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. –...
  • Page 66: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. (690 Enduro) – 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.
  • Page 67: Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro R) – 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. –...
  • Page 68: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.
  • Page 69: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.
  • Page 70 MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw all the way clockwise using a socket wrench.  Info Do not loosen nut  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline (690 Enduro) Compression damping, high-speed...
  • Page 71: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.
  • Page 72: Measuring The Unloaded Rear Wheel Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE Measuring the unloaded rear wheel sag 9.10 – Jack up the motorcycle. ( p. 61) – Measure the distance – as vertically as possible – between the rear axle and a fixed point, for example, a mark on the side cover. –...
  • Page 73: Checking The Static Sag Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the static sag of the shock absorber 9.11 – Measure distance of rear wheel unloaded. ( p. 70)  – Ask someone to help you by holding the motorcycle upright. – Measure the distance between the rear axle and the fixed point again. 0 0 A –...
  • Page 74: Checking The Riding Sag Of The Shock Absorber

    Adjusting the spring preload of the shock absorber 9.13 Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 75: Bleeding The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly. –...
  • Page 76: Cleaning The Dust Boots Of The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro) – 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. B00106-10 (690 Enduro R) –...
  • Page 77 MAINTENANCE WORK ON CHASSIS AND ENGINE – Push dust boot of both fork legs downwards.  Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
  • Page 78: Loosening The Fork Protection

    MAINTENANCE WORK ON CHASSIS AND ENGINE Loosening the fork protection 9.16 (690 Enduro) – Remove screws and take off clamp.  – Remove screws on left fork leg. Push the fork protection downwards.  – Remove the screws on the right fork leg. Push the fork protection downwards. 800075-10 (690 Enduro R) –...
  • Page 79: Positioning The Fork Protection

    10 Nm (7.4 lbf ft) Checking the steering head bearing play 9.18 Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
  • Page 80: Adjusting The Play Of The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. – Jack up the motorcycle. ( p.
  • Page 81 MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro) – Loosen screw . Remove screw   – Loosen and retighten screw  Guideline Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –...
  • Page 82: Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Screw, steering stem 20 Nm Loctite ® 243™ (14.8 lbf ft) – Check the steering head bearing play. p. 77) – Remove the motorcycle from the work stand. ( p. 62) Handlebar position 9.20 On the upper triple clamp, there are 2 holes at a distance to each other.
  • Page 83: Checking The Chain For Dirt

    MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Screw, handlebar support 40 Nm (29.5 lbf ft) Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Fit and evenly tighten the four screws ...
  • Page 84: Cleaning The Chain

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the chain 9.23 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 efficiency due to oil or grease on the brake discs. –...
  • Page 85: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension 9.24 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, bearings in transmission and rear wheel) are under additional load.
  • Page 86: Adjusting The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain tension 9.25 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, bearings in transmission and rear wheel) are under additional load.
  • Page 87 MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right ...
  • Page 88: Checking The Chain, Rear Sprocket And Engine Sprocket

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain, rear sprocket and engine sprocket 9.26 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Replace the rear sprocket or engine sprocket. Info The engine sprocket, rear sprocket and chain should always be replaced together.
  • Page 89 MAINTENANCE WORK ON CHASSIS AND ENGINE – Shift into neutral; pull the lower chain section with specified weight  Guideline Weight of chain wear measurement 15 kg (33 lb.) – Measure distance of 18 chain links in the lower chain section. ...
  • Page 90 MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Check the chain guide for wear. » If the chain guide is worn: – Change the chain guide. – Check that the chain guide is firmly seated. »...
  • Page 91: Adjusting Chain Guide

    Remaining screws, chassis 10 Nm (7.4 lbf ft) 100299-10 Checking the brake discs 9.28 Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
  • Page 92: Checking The Free Travel Of The Hand Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 at the contact surface of the ...
  • Page 93: Adjusting The Free Travel Of The Hand Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the hand brake to the handlebar and check free travel  ≥ 3 mm (≥ 0.12 in) Free travel of hand brake lever » If the free travel does not meet specifications: –...
  • Page 94: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 95 Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 96: Checking The Front Brake Linings

    9.33 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by 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...
  • Page 97: Changing The Front Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 98 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 99 MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- tons.
  • Page 100 MAINTENANCE WORK ON CHASSIS AND ENGINE – Check that leaf spring in the brake caliper and sliding plate in the brake caliper   support are seated correctly. 400418-10 – Insert the brake pads, insert the bolt and mount the split pin. –...
  • Page 101: Checking The Free Travel Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the free travel of foot brake lever 9.35 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.
  • Page 102: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
  • Page 103: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 104 Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 105: Checking The Rear Brake Linings

    If there is wear or tearing: – Change the rear brake linings. p. 103) 100260-10 Changing rear brake linings 9.40 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 106 Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 107 MAINTENANCE WORK ON CHASSIS AND ENGINE Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. 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! –...
  • Page 108: Removing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check that leaf spring in the brake caliper and sliding plate in the brake caliper   support are seated correctly. 400419-10 – Insert the brake pads, insert the bolt and mount the split pin. –...
  • Page 109 MAINTENANCE WORK ON CHASSIS AND ENGINE – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. 800078-10 – Remove screw  – Loosen screw  800079-10 – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.
  • Page 110: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove distance bushings  800080-10 Installing the front wheel 9.42 Warning Danger of accidents Reduced braking efficiency 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. –...
  • Page 111: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw  Guideline Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.
  • Page 112: Installing The Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not damaged. –...
  • Page 113 MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Remove bushing . Clean and grease the working surfaces of the bushing and shaft ...
  • Page 114: Checking The Rear Hub Rubber Dampers

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the motorcycle from the work stand. ( p. 62) Checking the rear hub rubber dampers 9.45 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation.
  • Page 115: Checking The Tire Condition

    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 characteristic 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. –...
  • Page 116: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after five years.
  • Page 117: Checking The Spoke Tension

    Correct the tire pressure. – Mount the dust cap. Checking the spoke tension 9.48 Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
  • Page 118: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. –...
  • Page 119: Mounting The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.50 (690 Enduro) – Hook slot of the seat onto screw , press the rear downward and at the same   time push it forward. – Push locking pin into lock housing and push the back of the seat down until ...
  • Page 120: Removing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the battery 9.51 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 121: Installing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery 9.52 – Slide the battery into the battery rack. Info The battery terminals must be at the rear. – Attach the positive cable and mount positive terminal cover  – Position retaining bracket ...
  • Page 122 – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 123: Changing The Main Fuse

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid ...
  • Page 124 – Insert the new main fuse. Fuse (58011109130) ( p. 178) Info If the new fuse burns out, contact an authorized KTM workshop. A reserve fuse is located in the starter relay.  – Check that the electrical equipment is functioning properly.
  • Page 125: Changing The Fuses Of Individual Power Consumers

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fuses of individual power consumers 9.55 Info The fuse box containing the fuses of individual power consumers is located under the seat. – Switch off all power consumers and the engine. – Remove the seat.
  • Page 126 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the faulty fuse. Guideline 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, turn signal, alarm system (optional)
  • Page 127: Adjusting The Engine Characteristic

    MAINTENANCE WORK ON CHASSIS AND ENGINE Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. – Mount the seat. ( p.
  • Page 128: Headlight Mask, Removing With Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting wheel until the desired digit is next to marking  Set the Map‑Select switch to Soft. – Set the adjusting wheel to position 1. Soft – reduced homologated peak performance for better driveability. Set the Map‑Select switch to Advanced.
  • Page 129 MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro) – Cover the fender with a cloth to protect it from damage. – Remove screws on the left and right.  – Tip the headlight mask forward and pull it off in an upward direction. 100296-11 –...
  • Page 130 MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro R) – Remove screw and take off the clamp.  – Release rubber band . Slide the headlight mask upward and tilt it forward.  800097-10 – Disconnect the electrical plug-in connection and remove the headlight mask with ...
  • Page 131: Installing The Headlight Mask With The Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the headlight mask with the headlight 9.58 (690 Enduro) – Connect the connectors of headlight and turn signal lights   – Check lighting function. 100294-11 – Remove the cloth from the fender, attach the headlight mask to points on the ...
  • Page 132 MAINTENANCE WORK ON CHASSIS AND ENGINE – Position brake-hose guide . Mount and tighten screws   Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 100296-12 (690 Enduro R) – Connect the electrical plug-in connection  800102-11...
  • Page 133: Changing The Headlight Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the headlight mask and fix it with rubber band  Info Make sure that the holding lugs engage in the fender. – Position the brake line and wiring harness. Position the clamp, and mount and tighten screw ...
  • Page 134 MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro) – Pull off connector  – Take off rubber cap of the headlight bulb.  600610-10 – Detach spring bar  – Remove headlight bulb  – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p.
  • Page 135: Changing The Parking Light Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn holder about 30° counterclockwise and remove it.  – Remove headlight bulb. – Insert a headlight bulb in the holder. Headlight (S2/socket BA20d) ( p. 179) – Insert the holder into the headlight housing and fix it by turning it approx. 30° clockwise.
  • Page 136: Changing The Turn Signal Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull bulb socket out of the reflector.  – Pull parking light bulb out of the bulb socket.  – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2,1x9,5d) ( p.
  • Page 137: Checking The Headlight Setting

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the screw on the rear of the turn signa housing. – Tilt headlamp diffuser forward carefully and take it off.  – Lightly squeeze the orange plug in the area of the holding lugs and take it off. ...
  • Page 138: Adjusting The Headlight Range

    MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Distance 5 m (16 ft)  – Check the headlight setting. The boundary between light and dark must be exactly on the lower mark for a vehicle with a rider. » If the boundary between light and dark does not meet specifications: –...
  • Page 139: Removing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE (690 Enduro R) – Loosen screw  – Adjust the light range by swiveling the headlight. Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (made in: Checking headlight adjustment). Info If you have a heavy payload, you will need to correct the headlight range.
  • Page 140: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. –...
  • Page 141: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws  Guideline Screw, air filter box top 2 Nm (1.5 lbf ft) – Mount the seat. ( p. 117) 100285-11 Cooling system 9.66 The water pump in the engine forces the coolant to flow. ...
  • Page 142: Checking The Antifreeze And Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling takes place by means of the air stream and a radiator fan , which is controlled by  a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
  • Page 143 MAINTENANCE WORK ON CHASSIS AND ENGINE Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Remove the cap of the compensating tank  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) »...
  • Page 144: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. –...
  • Page 145 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 146: Draining The Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE Alternative 2 Coolant (mixed ready to use) ( p. 189) – Mount the radiator cap. Draining the coolant 9.69 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...
  • Page 147: Filling The Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE Filling the cooling system 9.70 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor.
  • Page 148: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the cap from compensating tank and add coolant to the level shown in the  figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
  • Page 149: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  – When adjusting the clutch lever make sure that there is a minimum clearance to other parts of the vehicle.
  • Page 150: Checking The Play In The Throttle Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 9.73 – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...
  • Page 151: Adjusting The Play In The Throttle Cable

    Adjusting the play in the throttle cable 9.74 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut  – Set the play in the throttle cable by turning the adjusting screw ...
  • Page 152: Installing The Engine Guard

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the engine guard 9.76 – Slide the engine guard into holders at the rear.  – Position the engine guard. Mount and tighten screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 100199-10 Checking the engine oil level 9.77...
  • Page 153: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the engine oil and filter, cleaning the oil screens 9.78 – Drain the engine oil. p. 151) – Remove the oil filter. p. 152) – Clean the oil screens. p. 154) – Install the oil filter. p.
  • Page 154: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring.  – Completely drain the engine oil. 100200-10 – Thoroughly clean the oil drain plug with a magnet. –...
  • Page 155 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Place a suitable container under the engine. – Remove screws .
  • Page 156: Installing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the oil filter 9.81 – Insert oil filters   – Oil the O-rings of the oil filter covers. Mount oil filter covers   – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 100204-10 Cleaning the oil screens...
  • Page 157 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove plug with oil screen and the O-rings.   100205-10 – Remove plug with oil screen and the O-rings.   – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. 100206-10 –...
  • Page 158: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen with the O-rings.  – Mount and tighten screw plug with the O-ring.  Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 100208-10 Filling up with engine oil 9.83 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.
  • Page 159: Adding Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.
  • Page 160 MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.
  • Page 161: Troubleshooting

    Clean the socket connector and treat it with con- oxidized tact spray. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power. Air filter is very dirty Remove the air filter.
  • Page 162 Air in cooling system Fill the cooling system. p. 145) – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during the journey Lack of fuel Refuel. ( p.
  • Page 163 TROUBLESHOOTING Faults Possible cause Action – Time is not (correctly) displayed Fuse 2 blown Change the fuses of individual power consumers. p. 123) – Set the clock. ( p. 34) – Battery discharged Ignition not switched off when vehicle Recharge the battery. p.
  • Page 164: Blink Code

    BLINK CODE Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high...
  • Page 165 BLINK CODE Blink code FI of warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Error level condition Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high Blink code FI of warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short...
  • Page 166 BLINK CODE Blink code FI of warning lamp (MIL) 25 FI warning lamp (MIL) flashes 2x long, 5x short Error level condition Side stand switch - circuit fault Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Motor drive hall sensor - circuit fault Blink code FI of warning lamp...
  • Page 167 BLINK CODE Blink code FI of warning lamp (MIL) 54 FI warning lamp (MIL) flashes 5x long, 4x short Error level condition Secondary air valve - short circuit to ground or open circuit Blink code FI of warning lamp (MIL) 58 FI warning lamp (MIL) flashes 5x long, 8x short Error level condition EPT motor drive relay permission - signal fault...
  • Page 168 BLINK CODE Blink code FI of warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition CAN bus communication error Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition Motor drive voltage (internal) - circuit fault...
  • Page 169: Cleaning

    CLEANING Cleaning the motorcycle 12.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 170 CLEANING Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine is warm, applying the brakes occasionally. Info The heat produced causes water at inaccessible locations in the engine and the brakes to evaporate.
  • Page 171: Protective Treatment For Winter Operation

    PROTECTIVE TREATMENT FOR WINTER OPERATION Protective treatment for winter operation 13.1 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt. –...
  • Page 172: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 61) –...
  • Page 173: Putting Into Operation After Storage

    STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. Putting into operation after storage 14.2 –...
  • Page 174: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11.8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)
  • Page 175: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter, automatic decompressor...
  • Page 176: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite...
  • Page 177 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, locking lever 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, rocker arm shaft 12 Nm (8.9 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite...
  • Page 178 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –...
  • Page 179: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension 4860 MXMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel (690 Enduro) Front 250 mm (9.84 in) Rear 250 mm (9.84 in) Suspension travel (690 Enduro R) Front 275 mm (10.83 in)
  • Page 180 TECHNICAL DATA - CHASSIS Tire air pressure, offroad, single rider Front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Secondary drive ratio 15:45 Chain 5/8 x 1/4” X‑ring Steering head angle 63° Wheelbase (690 Enduro) 1,498±15 mm (58.98±0.59 in) Wheelbase (690 Enduro R) 1,504±15 mm (59.21±0.59 in) Seat height unloaded (690 Enduro)
  • Page 181: Lighting Equipment

    Metzeler Enduro 3 Sahara (690 Enduro R) 90/90 - 21 M/C 54S M+S TT 140/80 - 18 M/C 70R M+S TT To max.: 160 km/h (99.4 mph) Continental TKC 80 Continental TKC 80 Additional information is available in the Service section under: http://www.ktm.com...
  • Page 182: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Capacity - fuel 17.3 Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 192) Fuel reserve, approx. 2.5 l (2.6 qt.)
  • Page 183: Technical Data - Fork

    TECHNICAL DATA - FORK 690 Enduro 18.1 Fork part number 14.18.7E.11 WP Suspension 4860 MXMA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks...
  • Page 184: 690 Enduro R

    TECHNICAL DATA - FORK 690 Enduro R 18.2 Fork part number 14.18.7E.41 WP Suspension 4860 MXMA Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload...
  • Page 185: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER 690 Enduro 19.1 Shock absorber part number 15.18.7E.11 WP Suspension 4618 with Pro‑Lever deflector Shock absorber Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard...
  • Page 186: 690 Enduro R

    TECHNICAL DATA - SHOCK ABSORBER Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 395 mm (15.55 in) Shock absorber oil ( p. 191) SAE 2,5 690 Enduro R 19.2 Shock absorber part number 15.18.7E.41 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns...
  • Page 187 TECHNICAL DATA - SHOCK ABSORBER Weight of rider: 75… 85 kg (165… 187 lb.) 80 N/mm (457 lb/in) Spring length 220 mm (8.66 in) Gas pressure 10 bar (145 psi) Static sag 25 mm (0.98 in) Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 405 mm (15.94 in) Shock absorber oil (...
  • Page 188: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) – Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) ® Bolt, foot brake lever stub 6 Nm (4.4 lbf ft) Loctite...
  • Page 189 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, magnetic holder on side stand 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, radiator bracket 5 Nm (3.7 lbf ft) ® Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite 243™...
  • Page 190 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, steering stem 20 Nm (14.8 lbf ft) Loctite 243™ – Screw, top triple clamp 17 Nm (12.5 lbf ft) – Upper fuel tank screw 20 Nm (14.8 lbf ft) ® Engine carrying screw 45 Nm (33.2 lbf ft) Loctite 243™...
  • Page 191: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 192: Engine Oil (Sae 10W/60)

    196) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
  • Page 193 – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 194 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)
  • Page 195: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and preserving materials for metal, rubber and plastic Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Protect & Shine 645...
  • Page 196 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Fett 2000 Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Off-road chain spray Guideline – ® KTM recommends Motorex products.
  • Page 197 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
  • Page 198: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
  • Page 199: Index

    INDEX rear brake, checking ......103 INDEX Brakes ........53 Accessories .
  • Page 200 INDEX indicator lamps ......24, 29 removing ........149 ODO display .
  • Page 201 INDEX Fork protector positioning ....... . . 77 Ignition lock ........22 remove .
  • Page 202 INDEX Parking ........54 Seat Parking light bulb mounting...
  • Page 203 INDEX Steering lock ........22 Stopping ........54 View of vehicle Storage .
  • Page 204 *3211511en* 3211511en 09/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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