KTM 690 Enduro R 2018 Operating instructions

REPAIR MANUAL 2018
690 Enduro R
Art.
no.
3206323en

Read
this
repair
manual
carefully
and
thoroughly
before
beginning
work.
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 model
series.
We
reserve
the
right
to make
changes
in the
interest
of technical advancement without
updating
this
repair
manual
at
the
same
time.
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
GmbH
specifically
reserves
the
right
to
modify
or
delete
technical
specifications, 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
figures
and
descriptions,
misprints,
and
other
errors.
The
models
portrayed
partly
contain
special equipment
that does
not
belong
to
the
regular
scope
of
supply.
© 2017
KTM
Sportmotorcycle
GmbH,
Mattighofen
Austria
All
rights
reserved
Reproduction,
even
in
part,
as
well
as
copying
of
all
kinds,
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
assur-
JUV
ance
processes
that lead
to
the maximum
possible
quality
of the
products.
Sad
Issued
by:
TUV
Management
Service
REG.NO,
12 100 6061
KTM
Sportmotorcycle
GmbH
StallhofnerstraBe 3
5230
Mattighofen,
Austria
This
document is
valid
for the
following
models:
690 Enduro R EU
(F9703R8)
690 Enduro R US
(F9775R8)
3206323en
09/2017

MEANS OF REPRESENTATION
.........ccseecneeeeee 7
Asi.
SVYMBGIS
US6E)
cccssniccsesrncaserimauvavcraewan
7
1.2 FOrMats USE0
svc cccsiscsssvssneeweimesearssawewee
7
SAFELY ADVIC
Excise
mney
8
21
Repair
MANUAL
wsccccsccseeesnevoenmenasevenansns
8
2.2
Safety
GOAVICE
cccsunenenacecunmessinnesoncnersensn
8
2:3
Degrees
of risk
and
symbols.............068
8
2.4
WOEK TUNES
ios ssnscasarescewerresmaencenanenevopenne
8
IMPORTANT NOTES
xccccnnnnesrena
9
301 Manufacturer and
implied
warranty......
9
3.2
Operating
and
auxiliary
substances...... 9
3:3
Spare
parts,
ACCESSOFIES
..........e cesses eee
9
3.4
FISUIES
oc ecceccccceceeceecseeeeeeeneeneeneeueenes
9
SERIAE NUMBERS
visvsssscvisavecaswerccwsavecavens
10
4.1 Chassis NUMbE?L
..............cceeeeeeeeeeeeeee
10
4.2
Type
label
......... ec ceeeeeeeeeceeeeeeeeeeeee es
10
4.3
Engine
MUMbE?
..........:.ceeeeeeeeeeeeneeeees
11
4.4
K@Y
MUMDED.....
cee eeceeee ee eeeeeeeeeneeneenes
11
4.5 Fork
part
NUMDEr
..........cccee cee eeee eee eeee
11
4.6 Shock
absorber
article
number..........
11
MOTORGYGEE
cccrcsacccrsvecsincesaveracocosnisennnvraens
12
5.1
Raising
the
motorcycle
with
a
lift
StANG
seccesinwcdecvisaccvspeseersarewenswevwaaveaays
12
5.2
Removing
the
motorcycle
from
the
Vift
Sta
oo...
cccceeeeceeeeeeeeeeeeeeeeeeeeneeeees
12
5.3
Raising
the
motorcycle
with the work
SEAAC
se
usiaecapavvgeaaiadcuesarapeestreowaaeans
12
5.4
Removing
the
motorcycle
from
the
WOFK Stan
ssicacesncnscvensvrseoswvicauvavevawns
13
5:5
Starting
the
Vehicle
.........c.cccccecseseeees
13
5.6
Starting
the
motorcycle
to
check the
FUNCTION
.0.. 2... cece cee cece eee eeeeeeteeeeeeeeeeees
14
FORK,
TRIPLE: CLAMP.
wise
csvsscssanseanssaeevavvaases
16
6.1
Adjusting
the
compression damping
Of
The
TOK
isiccisvseweresavnaeaveresens
16
6.2
Adjusting
the rebound
damping
of
the FOrK
.......ccceccceseeceeeeeeeceeeteceeeneaeues
16
6.3
Bleeding
the fork
legs.............cccseeeees
17
6.4
Cleaning
the dust boots of the fork
leSS
eis
eR ae
17
6.5
Loosening
the fork
protection
............
18
6.6
Positioning
the fork
protector
............
18
6.7 Removing
the
fork
legs
.............0:0eee
18
6.8
Installing
the
fork
legs...
eee ee
20
6.9
Disassembling
the
fork
legs...............
22
6.10
Checking
the
fork
legs................ceceee
25
6.11
Assembling
the fork
legs................06
26
6.12
Checking
the
play
of the
steering
h@ad
Harins
vicsescsiccswsweacsesnew
31
10
11
6.13
Adjusting
the
steering
head
bearing
DIBY
iesccvacasncsvauwssavensanvinsevsvivswxnisansnes
HANDLEBAR;
CONTROLS
S:escxsenerenes
Tad Handlebar
position
.............:ccceeeeeeeees
7.2
Adjusting
handlebar
position.............
7:3
Changing
the
throttle
grip...
cess
FRAME
acssnma annem
8.1
Removing
the
engine guard...............
8.2
Installing
the
engine
guard
...............
SHOCK
ABSORBER,
SWINGARM
...............+5
9.1
Adjusting
the
high-speed
compression damping
of
the shock
ADSOMDEL.......cceseseeceeeeeneeeeenseneeneenenees
9.2
Adjusting
the
low-speed
compression
damping
of
the
shock
ADSOl DEP
swe
cscwwesvacrssarecrwevesersesesescaneees
9.3
Adjusting
the rebound
damping
of
the shock absorber
............:scscceeeeeeeees
9.4
Measuring
the unloaded
rear
wheel
SOR
sistent niin
9.5
Checking
the
static
sag
of
the
shock
ADSOMDOliscsasiniscesawesseeranvimeewnnvenoreanvecens
9.6
Checking
the
riding
sag
of
the
shock
ADSOFDELS....
ec
ceeeeseeeeeeeeneeeeeneeseeereneaees
9.7
Adjusting
the
spring
preload
of the
shock absorber-sssssssenecnreccn
9.8
Adjusting
the
riding
sag..................0
9.9
Removing
the shock absorber............
9.10
Installing
the shock absorber.............
9.11
Servicing
the
shock
absorber.............
9.12
Removing
the
SPring.......ccccccccceseneeens
9.13
Dismantling
the
damper
...................
9.14
Disassembling
the
piston
rod
............
9.15
Checking
the
damper
...........cceceeeeee
es
9.16
Removing
the heim
joint............0......
9.17
Installing
the heim
joint...................
9.18
Assembling
the
piston
rod..............04
9.19
Assembling
the
damper.............00.08
9.20
Bleeding
and
filling
the
damper
........
9.21
Filling
the
damper
with
nitrogen........
9.22
Installing
the
spring
.............ceeeeeeenes
EXHAUST
iccesscnsusscnonurecsmawasxwusereomeneuexencenes
10.1
Removing
the manifold.........0.....0.....
10.2
‘Installing
the
manifold
....................
10.3.
Removing
the main silencer..............
10.4
‘Installing
the
main silencer...............
AIR
FILTER
wu... cccceeccecceeeceecueeeeeeeeeueeneenees
11.1
Removing
the air filter............00..0.....
11.2
Installing
the air filter........0..
11.3.
Removing
the air filter box................

12
13
14
L5
11.4
—
Installing
the air
filter
box............0... 70
FUEL
TANK,
SEAT,
TRIM
...............ccceeeeeeeees
72
12.1
Opening
the filler
Cap...........
cee ceseeees
72
12.2
Clostnig-titler:
Capissscssssesvisissscarcascsces
42
12.3.
Removing
the
seat
........ cece ee eees
73
12.4
Mounting
the seat...
ee eeees
73
12.5
Taking
off
the
side
cover................0
73
12.6
Mounting
the
side
cover...............c060
74
12.7.
Checking
the
fuel
pressure................
74
12.8
Changing
the
fuel
screen..................
76
12.9
Changing
the fuel
filter................02...
TT
12.10
Changing
the fuel
pump................0.
81
WHEELS ...
occ ceeceeeseeeeeeeeseaueeneeaueenaeeaeeeneenuees
84
13.1
Checking
the
tire air
pressure............
84
13.2
Checking
the
tire
condition
...............
84
13.3.
Checking
the brake
discs..............00 85
13.4
Checking
the
spoke
tension...............
86
13.5
Checking
the rim
run-out..................
86
13:6: Front wheehiisssscsasssvsscsamerinseesi 87
13.6.1
Removing
the
front
wheel.............
87
13.6.2
Installing
the front
wheel..............
88
13.6.3.
Changing
the
front
brake
disc
.......
89
13:7 Rear wheel
viiisicnciiiinnniiisn
90
13:71
Removing
the
rear
wheel .............. 90
13372
Installing
the
rear
wheel
...............
90
13.7.3.
Changing
the
rear
brake disc......... 92
13.7.4
Checking
the chain tension........... 92
13.7.5
Adjusting
the
chain tension
..........
93
13.7.6
Adjusting
chain
guide...
94
LOVE
Checking
the
chain,
rear
sprocket,
engine
sprocket,
and
CHAIN
BUIdE
.....ciccesseceeeeeeeeeneeeean es
94
13.7.8
Cleaning
the
chain...........cceeeeees
96
13.7.9
Checking
the
rear
hub rubber
GaMPeOrsesssnsnncnin
es
97
WIRING HARNESS,
BATTERY.........::ccceeeeeees
99
14.1
Removing
the
battery
............c cee
99
14.2
Installing
the
battery
................ccee
100
14.3.
Disconnecting
the
battery
...............
101
14.4
Connecting
the
battery
..............0..
101
14.5
Recharging
the
battery
...............0..
102
14.6
Checking
the
charging voltage.........
103
14.7.
Checking
the
open-circuit
current....
105
14.8
Changing
the main
fuse..................
106
14.9
Changing
the fuses of individual
POWES
CONSUMESS
v.ccsescssonssssevcrerevees
107
14.10
Adjusting
the
engine
characteristic
sssiiscasiaseaisin ties
108
14.11
Diagnostics
connector
............c.ceeeee
109
BRAKESYSTEM
ccoscsswsssconerocsrenevexiniceseconeney
110
15.1 Antilock brake
system
(ABS) ...........
110
16
17
15.2
Checking
the
front
brake
linings......
15.3.
Changing
the front brake
linings......
15.4
Checking
the free travel of the
hand
brake
lever
............c.0cceceeeeseees
15.5
Adjusting
the free travel of the
hand brake lever
.........cceeeeeeeeeeeeeeees
15.6
Checking
brake fluid level of front
Brake
:cissnascassmiusmnaresaeuerreieeins
15.7
Topping
up
brake
fluid of front
DE
AKG:
iccansscveweverianevernaeewsszescenaeceoeas
15.8
Changing
the
front
brake
fluid.........
15.9
Checking
the
rear
brake
linings
.......
15.10
Changing
the
rear
brake
linings.......
15.11
Checking
the free travel
of foot
Drake I@VEr
oo... eeceeceeeeeeeeeeeeeeneeeeae ens
15.12
Adjusting
the basic
position
of
the
foot brake lever
viii aeiseiiareueianen
15.13
Checking
rear
brake fluid level
........
15.14
Adding
rear
brake
fluid...
15.15
Changing
the
rear
brake fluid..........
LIGHTING
SYSTEM,
INSTRUMENTS...........
16.1 Combination instrument
.................
16.1.1
Setting
the kilometers
or
miles...
16.1.2
Setting
the: clock
visiscaissicaveees
16.1.3
Setting/resetting
CGisplay
TRIP L.sssissscersrevessssaseces
16.1.4
Setting/resetting
display
TRIP 2........cccecceceeeeeeeeees
16.1.5
Setting
the wheel
CIFCUMPErENCE
........
2. cee ceceeee ee eeees
16.2
Checking
the
headlight setting
........
16.3
Adjusting
the
headlight
range..........
16.4.
Removing
the
headlight
mask with
The
HGAGIIBAL.
.csissecsssssseereneverssseseces
16.5
Installing
the
headlight
mask
with
the
headlight
csscaicsucaiiniscees
16.6
Changing
the
parking
light
bulb.......
16.7
Changing
the
headlight
bulb...........
16.8
Changing
the
turn
signal
bulb
.........
ENGIN
Ee
csscerssmnscnvinvexconmnvennnnexnicsscnnsens
17.1
Removing
the
engine...........cceeeeee
17.2
Installing
the
engine...........ccceeeeee
17.3.
Engine
disassembly.............cc0c:00000
17.3.1
Clamping
the
engine
into the
engine assembly
stand
...............
17.3.2
Draining
the
engine
oil
...............
17:.3:3
Removing
the
starter
motor.........
17.3.4
Removing
the valve
cover............
17.3.5
Removing
the alternator
cover.....
17.3.6
Removing
the
spacer................08
TES7
Removing
the
gear
position
SOMSOP...cicceecssccueeeeeeueeeeeeneeeneeenes
L738
Removing
the
oil filter................
115

17.3.9
Removing
the thermostat............
143 17.4.13
Checking/measuring
the
piston....
166
17.3.10
Setting
engine
to
ignition
top
17.4.14
Checking
the
piston ring
end
ead
CONEr
se cscsesccscesseeceweesssvscas
143
PAD
sccave cocmssvecnesarwenmwesarseseneseanes
167
17.3.11
Removing
the
spark plugs...........
144 17.4.15
Determining
the
piston/cylinder
17.3.12
Removing
the
timing
chain
mounting
clearance..........c.cceeeeee 167
TENSIONEL.....cceceeeceeeeeeeeeeaneeueennes
144
17.4.16
Checking
oil
pumps
for
wear.......
167
17.3.13.
Removing
the camshafts............. 144 17.4.17
Replacing autodecompressor.......
169
17.3.14
Removing
the
cylinder
head........
145 17.4.18
Preparing timing
chain tensioner
17.3.15
Removing
the
piston
.......cccccrrers
145
TOF
INStallationisiwsiswwenawers
170
17.3.16
Removing
the water
pump
17.4.19
Checking
the
timing
assembly.....
171
IMpellOPsvcasscecrceeueyeeseceeeey
146 17.4.20
Removing
the rocker
arm............
172
17.3.17
Removing
the rotor.....................
146 17.4.21
Changing
the camshaft
bearing...
172
17.3.18
Removing
the
timing
chain 17.4.22
Removing
the valves................... 174
(AU Sovisrnssniwenccessswasuesmeecsmesunansess
147
17.4.23
Checking
the valves
...............005+
174
17.3.19
Removing
the
timing
chain and
17.4.24
Checking
valve
springs
.......:0000
175
timing
chain
sprocket...
147
17.4.25
Checking
valve
spring
retainer..... 175
17.3.20
Removing
the
ignition pulse
17.4.26
Checking
the
cylinder
head......... 175
generator
So eo een arta
148
17.4.27
Installing
the valves
..........c eee
176
17.3.21
Removing
the clutch
cover..........
148
17.4.28
Installing
the rocker
arm.............
Life
17.3.22
Removing
the
spacer
and
17.4.29
Disassembling
the
antihopping
RPRING
ccancevesscsnnnnennerisanarionaires
149
Clit
hiessisessmesencsseenenns
177
17.3.23
Removing
the clutch basket........
149
17.4.30
Checking
the Clutch
........csseesc-0e-
178
17.3.24
Removing
the
primary
gear
euwarivesis
151
17.4.31
Preassembling
the
antihopping
17.3.25
Removing
the
starter
drive
..........
151
CAC Miwsonwssneeianenvosenenenevowunexs 180
17.3.26
Removing
shift shaft
............0..
152
17.4.32
Checking
the
shift mechanism.... 181
17.3.27
Removing
shift
drum
locating......
152
17.4.33
Preassembling
the
shift shaft...... 182
17.3.28
Removing locking
lever............0. 152
17.4.34
Disassembling
the main
shaft
.....
183
17.3.29
Removing
the
oil
pumps.............
152
17.4.35
Disassembling
the
17.3.30
Removing
the
left
engine
case.....
154
CouNtershathisiisccicssisecdssssccasseases
184
17.3.31
Removing
the crankshaft and
17.4.36
Checking
the transmission.......... 184
DAIANCEr SNAlE
«...0crenceeeconcseneneenene
154
17.4.37
Assembling
the main shaft.......... 186
17.3.32
Removing
the transmission
17.4.38
Assembling
the countershaft....... 187
shafts
sasedahnasenstbeenstiiecboesveneniones
155
17.4.39
Checking
the
starter
drive
...........
189
17.4
Working
on
individual
parts.............
156
17.4.40
Checking
freewheel
........csssee+ee00-
190
17.4.1
Working
on
the
right
section
of
17.4.41
Removing
freewheel
................065
190
the
Engine
Case
........ccceeceeceee eee ee
156
:
: .
17.4.42
Installing
freewheel............ccceeeee
190
17.4.2
Working
on
the
left
section
of
17.5
Ehgineessembly
191
the
engine
Case
.........ccsesseeeeeeeee
157
:
a
a
MOR
AeeSecesnae
ee
17.4.3
Work
on
the clutch
cover............
159
17.5.1
Installing
the
transmission
; ,
ShaltS
scsi aes
191
17.4.4
Removing
crankshaft
bearing
‘
inner
tinea
160
17.5.2
Installing
crankshaft and
: 4
HalanGer Shaft
ccwcvescivesccrewsseeacee
193
he
Retpoving
the. drive wheel of the
17.5.3
_
Installing
the
left
engine
case.....
193
balancer
shaft
« cscavisseseviseevavss
160
—
. ciel
iaiaiiiaaialia
17.4.6
Changing
the
connecting
rod,
17.5.4
Installing
the
oil
PUMPS
.icsecseecenes
194
conrod
bearing,
and crank
pin.....
160
17.5.5
Installing locking
lever
..........000.
195
17.4.7.
Checking
crankshaft
run-out at
17.5.6
Installing
shift
drum
locating......
196
bearing
pinievcssseiuuscacavssserecuaeveaes
162
17.5:7
Installing
shift shaft............0.
196
17.4.8
Installing
balancer shaft drive
L725:8
Installing
the starter drive...........
196
WCE!
cccsvcvcccnscnissasseveceewrissavaviven
162
17.5.9
Installing
the
primary
gear..........
197
17.4.9
Installing
crankshaft
bearing
17.5.10
Installing
the clutch basket.........
197
INMON
PING
«0... eee eee ee eee e eee eeeeeeeeeeeee
163
17.5.11
Installing
the
spacer
and
17.4.10
Measuring
axial clearance of
SPVING
... ec eee
cee eeceeeeeeeeeeeneeseeeeeeees
199
crankshaft and balancer shaft..... 164
17.5.12
Installing
the clutch
cover ..........
199
17.4.11
Cylinder
-
Nikasil® coating
..........
165
17.5.13
Installing
the
ignition pulse
17.4.12
Checking/measuring
the
PEeratoM
vss newer
200
CVIINGER
ssasievesanrcewesiaceacanaeeeuxrvene
165

18
19
20
21
17.5.14
Installing
timing
chain
and
timing
chain
sprocket.................
Installing
the
timing
chain rails...
Installing
the
rotor
................0
Adjusting
crankshaft
position
SeENSOr
CiStanCe........ccceeeeeeeeneenees
Setting engine
to
top
dead
175.15
17.5.16
17.5.17
17.5.18
17:.5:19
17.5.20
L75;21
L75:22
E7.5:23
[AStALE:
PISTON
savcviwsvessisosevavavese
Installing
the
cylinder
head.........
Installing
camshafts...................
Installing timing
chain
TOMSIONEL.....cccceeeceeeeeceereeeeeeeeaeens
Checking
valve
clearance............
Adjusting
the valve clearance......
Installing
the
spark plugs............
Installing
the thermostat.............
Installing
the oil filter...
Installing
the
gear
position
SONSOl
esis
Installing
the
spacer...................
Installing
the alternator
cover......
Installing
oil
Screens ............0
Installing
the
starter motor..........
Installing
the
valve
cover ............
Removing
the
engine
from
the
engine assembly
stand
...........00..
CLUTCH
1.0... ee ceccceeeeee cece eeeeeeeeeeeeeeeeeeeeeeaees
18.1
17,.5.24
175329
17.5.26
17.5.27
17.5.28
175.29
17.5.30
1725.31
17.5.32
17.5:33
17.5.34
17.5.35
Checking/correcting
the fluid
level
of
the
hydraulic
clutch..........cceeeee
18.2
Changing
the
hydraulic
clutch
Wititheccrnncamamncmeree
SHIFT
MECHANISM
.........ccceeceeceeeeeeeeeennees
19.1
Changing
the
gear
position
sensor....
19.2
Programming
the
gear
position
SONSOM
..
ee eeeeeeeeeeneeeeeeeeseeeeeaeeeeeeeees
WATER
PUMP,
COOLING SYSTEM.............
20.1
20.2
Draining
the
Coolant.........:csseeneeeeens
Filling/bleeding
the
cooling
SYSHOM
wiisavecsisvarccsvavennveieivansercaiys
Checking
the antifreeze and
GOGIANE EVEL
ous cevccnexermewacnevsessanereess
Checking
the coolant level
..............
Changing
the
coolant............cceseeeees
20.3
20.4
20.5
LUBRICATION SYSTEM......0:c0cscccesssccessneees
21.1
21.2
21.3
21.4
Oil CIFCUI
tL...
ec cecseeeee eee eeeeeneeeeeuenaees
Checking
the
engine
oil
level...........
Checking
the
engine
oil
pressure
.....
Changing
the
engine
oil
and
filter,
cleaning
the oil
screens..................
201
216
22
25
26
27
28
21.5
Draining
the
engine
oil
................08.
21.6
Removing
the oil filter.................0.
21.7
‘Installing
the oil filter.....................
21.8
Cleaning
the
oil
screens..................
21.9
Filling
up
with
engine
oil
................
21.10
Adding engine
Oil...
eee
IGNUFION SYSTEM.
.sssccisanecnseuwsasscewescaseaseae
22.1 Alternator
-
checking
the stator
WITTKIAE
.ccascssanccvssvancversauninessaveasasas
22.2
Ignition
coil
-
checking
the
primary
WINING
..........ececeeeeceeeeeeeeseeeeeeeeeeees
THROTTLE:
VALVE: BODY
-sssscixssasxccnccscinweees
23.1
~Performing
the initialization
run......
23.2
Resetting
the
engine
electronics
CONTKO!
UNE
secssaviessseisenccavawsencrweawes
TECGHNIGAL DATAsssecwsnnnnenineean
2A,
ERBINE
csssonsaeesurauemesareruceemensienpee
24.2
Engine
tolerance,
wear
limits
..........
24.3
Engine tightening
torques...............
24.4.
(GaDACTIOS
a csavaxseneanssaveynagereneesnaneys
24.4.1
EPI
SOE
sicissvesssemmsavexevessaseaceys
24.4.2 CODA
bss
waavsieassensressauxtessvanrseacas
24.4.3 FUE)
oyscncnssannnerapsnsransausisesvanneacas
24A.G
|
CHASES:
evescsicssscovsasueseacssnaseswsureenese
PA.6 ElectriCal
SYStEM:
ciscscccccscccecesesveenens
PAP’
°
THES
cncscvesnsacrswssnxeamamnevevnvesns
PAB
FO i
cisissvesrmvarcrswsvvaxeassaenevevevees
24.9: ‘SHOCK: ADSOMDER
cosciscncccwssnenessxmeesens
24.10 Chassis
tightening
torques
...........065
CLEANING/PROTECTIVE
TREATMENT........
25.1
Cleaning
the
motorcycle
.................
25.2 Checks and maintenance
steps
for
winter
Operation
.............csseseeeeeeeeees
STORAGE
wesssersmevouarmarnannvoausepaxememace
2621:
‘Stage
vnccasscnawsrcavasisasccss
26.2
Preparing
for
use
after
storage.........
SERVICE SCHEDULE ................ceecceeeeeeee
ees
27.1 Additional
information...................
27.2
Required
Work
..........ccceceeeeseeeeeeeeees
27.3. Recommended work............0.:0ceseeee
WIRING (DIAGRAM
sisaiaiaaiantincsaia
28.1.
PAPE
OLOF TU
wccrsssacsvessanvessssaveseasas
28:2
PARC
O02 OF
LA
ccssasssccscvenscnewserxennece
PSB
PAGO
OS GPT
ce cocusxensscsenenwesieewensee
PEA
PARE
QMOf
EL
scvcsasscncnvesneesessnaesens
235
Page
OS: OF
Uh
sccsmecnencsnecensnansscns
28:6:
Paste
OG OF A:
vccswssvincccssneeressrnsewes
28:7
PagecOF
OF LU biasissieccivsscasaseesessvecas

28:38
Page
O8
0f 21
scenes
270
28:9
Page
OS of 11
susie
272
28.10
Page
1Ovof 11
causes:
274
28.11.
Page
ll:of
11]
causes:
276
29) SUBSTANCES
ccsscesscevessnnsenevenaveseoanemnmneenne
278
30 AUXILIARY SUBSTANCES ..........:cesseeeeeeeeee 280
31 SPECIAL TOOLS ........cceceeeeceeeeeeeeeeeeeeeeeeeees 282
32 STANDARDS
uccesccscsssscsscerssazsassazeeceevessasnsas
301
33 INDEX
OF
SPECIAL TERMS.
...........ccccceeereee
302
34 LIST OF ABBREVIATIONS........:::cseeeseeeeeeees 303
INDEX
sssscss asics
304

The
meaning
of
specific
symbols
is described
below.
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).
Indicates
a
page
reference
(more
information is
provided
on
the
specified page).
Indicates
information
with
more
details
or
tips.
-
x
SN
Indicates the
result of
a
testing
step.
»
Indicates
a
voltage
measurement.
Indicates
a
current measurement.
Indicates
a
resistance measurement.
Indicates
the
end of
an
activity including potential
rework.
The
typographical
formats used in this document
are
explained
below.
Proprietary
name
Indicates
a
proprietary
name.
Name®
Indicates
a
protected
name.
BrandTM Indicates
a
brand available
on
the
open
market.
Underlined
terms
Refer
to technical details
of the
vehicle
or
indicate
technical
terms,
which
are
explained
in
the
glossary.

Read this
Repair
Manual
carefully
and
thoroughly
before
beginning
work.
It
contains
useful information
and
tips
that
will
help
you
repair
and maintain
your
vehicle.
This
manual
assumes
that
the
necessary
special
KTM
tools and
KTM
workplace
and
workshop equipment
are
available.
A number of
safety
instructions
need to be
followed
to
operate
the
model described
safely.
Therefore
read this
instruction and all further instructions included
carefully.
The
safety
instructions
are
highlighted
in the
text
and
are
referred
to at
the
relevant
passages.
e
Info
I
Various
information and
warning
labels
are
attached
in
prominent
locations
on
the
model described. Do
not
remove
any
information
or
warning
labels.
If
they
are
missing,
you
or
others
may
not
recognize dangers
and
may
therefore
be
injured.
Warning
Indicates
a
danger
that
is
likely
to lead to
fatal
or
serious
injury
if
the
appropriate
measures
are
not taken.
A
Caution
Indicates
a
danger
that
may
lead to
minor
injuries
if the
appropriate
measures are
not
taken.
Note
Indicates
a
danger
that
will
lead
to
considerable machine
and material
damage
if
the
appropriate
measures are
not
taken.
Warning
ae
Indicates
a
danger
that
will
lead
to
environmental
damage
if
the
appropriate
measures are
not
taken.
Special
tools
are
necessary
for certain tasks. The
tools
are
not
a
component
of
the
vehicle,
but
can
be
ordered
using
the number
in
parentheses.
Example:
bearing
puller
(15112017000)
During
assembly,
use new
parts
to
replace parts
which
cannot be reused
(e.g.
self-locking
screws
and
nuts, seals,
sealing rings, O-rings, pins,
and lock
washers).
In the
case
of certain
screws,
a
thread locker
(e.g.
Loctite®)
is
required. Apply
according
to
the manufacturer's
instructions.
After
disassembly,
clean the
parts
that
are
to
be reused and check them for
damage
and
wear.
Change damaged
or worn
parts.
After
completing
a
repair
or
service
work,
check
the
operating
safety
of the vehicle.

The
work
specified
in
the service
schedule
may
only
be
performed
in
an
authorized KTM
workshop
and must be
recorded
in both the
Service
&
Warranty
Booklet and in KTM
Dealer.net,
otherwise
any
warranty
coverage
will
become
void.
Damage
or
secondary
damage
caused
by
tampering
with and/or conversions
on
the vehicle
are
not
covered
by
the
warranty.
Additional information
on
the
manufacturer
or
implied
warranty
and
the
procedures
involved
can
be found in
the
Service &
Warranty
Booklet.
Warning
Environmental hazard
Improper handling
of fuel is
a
danger
to
the environment.
—
Do
not
allow
fuel
to enter
the
groundwater,
the
soil,
or
the
sewage
system.
Use the
operating
and
auxiliary
substances
(such
as
fuel and
lubricants)
as
specified
in the manual.
Only
use
spare
parts
and
accessories
approved
and/or recommended
by
KTM.
KTM
accepts
no
liability
for
other
products
and
any
resulting damage
or
loss.
The
current
KTM
PowerParts
for
your
vehicle
can
be
found
on
the KTM website.
International KTM Website:
http://www.ktm.com
The
figures
contained in the
manual
may
depict
special equipment.
In the
interest
of
clarity,
some
components
may
be shown
disassembled
or
may
not
be
shown
at
all.
It
is
not
always
necessary
to
disassemble
the
component
to
perform
the
activity
in
question.
Please
follow
the
instructions
in
the text.
wo

The
chassis
number
ay
is
stamped
on
the
steering
head
on
the
right.
/
\
:
401945-10
(690
Enduro
R
EU)
The
type
label
(1)
is located
on
the
right
side of the frame.
/
LN
/
/
i
Nee
\
/
//\
Ho1049-10
(690
Enduro R
US)
The
type
label USA
@
is located
on
the
right
side of the
frame.
The
type
label
Canada
2]
is
located
on
the
left side of
the
frame.
A
_\_\
\
HO1O55-10
10

The
engine
number
oO
is
stamped
on
the
left
side of the
engine
under the
engine sprocket.
401949-
10
The
key
number
@
can
be
found
on
the
KEYCODECARD.
O
Kia
e
Info
You need
the
key
number to order
a
spare
key. Keep
the KEYCODECARD
in
a
safe
place.
402241-10
The fork
part
number
oO
is
stamped
on
the
inner
side of
the
fork
stub.
401947-10
The shock absorber article number
@
is
on
the left side of the
———~"_402025-10
shock absorber.
,
/
\
\
Z
j
1

Note
Danger
of
damage
_
The
parked
vehicle
can
roll
away
or
fall
over.
—
Park the vehicle
on a
firm and level surface.
—
Use the underride
guard
underneath the
engine
to
raise the
vehicle.
”
Neither wheel is
in
contact
with the
ground.
—
Secure the
motorcycle against falling
over.
4
401942-01
Note
Danger
of
damage
The
parked
vehicle
can
roll
away
or
fall
over.
—
Park the vehicle
on a
firm and level surface.
—
Remove the
motorcycle
from
the
lift
stand and
rest
it
on
side
stand
@.
—
Remove the lift stand.
4
OQ O)
401943-10
Note
Danger
of
damage
The
parked
vehicle
can
roll
away
or
fall
over.
—
Park the vehicle
on
a
firm
and level
surface.
—
Mount
special
tool
on
the footrests.
Work stand
attachments
(75029036000)
('~
p.
289)
300579-10
12

Position the
motorcycle upright, align
the
special
tool,
and
raise the
motorcycle.
|
Work stand
(62529055100)
('"
p.
287)
4
300201-10
Note
Danger
of
damage
The
parked
vehicle
can
roll
away
or
fall
over.
—
Park the
vehicle
on a
firm and level
surface.
-
Secure
the
motorcycle against falling
over.
—
Remove
the work stand and
lean
the
vehicle
on
the side stand.
—
Remove
the
special
tool.
300579-10
Danger
Danger
of
poisoning
Exhaust
gases
are
toxic and
inhaling
them
may
result
in unconsciousness
and
death.
—
Always
make
sure
there
is
sufficient ventilation
when
running the
engine.
-
Use
an
effective exhaust extraction
system
when
starting
or
running
the
engine
in
an
enclosed
space.
A
Caution
Danger
of accidents Electronic
components
and
safety
devices will
be
damaged
if the
battery
is
discharged
or
missing.
—
Never
operate
the vehicle with
a
discharged battery
or
without
a
battery.
Note
Engine
damage
High
revving speed
with
a
cold
engine
negatively impacts
the
lifespan
of the
engine.
—
Always
run
the
engine
warm
at
a
low
speed.
13

—
Turn the
emergency
OFF switch
to
the
position
©.
-—
Switch
on
the
ignition
by
turning
the
ignition
key
to
position
ON ©).
~”
After
you
switch
on
the
ignition,
you
can
hear the
fuel
pump
working
for about
two
seconds. The function check
of the combination instrument is
run
at
the
same
time.
()
”
The
ABS
warning
lamp lights
up
and
goes
back out after
starting
off.
B00103-10
—
Shift
gear
to
neutral.
&
The
green
idle indicator
lamp
N
lights
up.
—
Press the electric
starter
button
@.
e
Info
il
Do
not
press
the
electric
starter
button
until
the
combi-
nation instrument function check is finished.
When
starting,
DO
NOT
open
the throttle. If
you open
the throttle
during
the
starting
procedure,
fuel is
not
injected
by
the
engine
management system
and the
engine
cannot
start.
Press
the starter
for
a
maximum of 5
seconds.
Wait for
a
least
5 seconds before
trying again.
This
motorcycle
is
equipped
with
a
safety
starting
sys-
tem.
You
can
only
start
the
engine
if
the
transmission
is in neutral
or
if
the clutch lever is
pulled
when
a
gear
is
engaged.
If
the
side
stand
is folded
out
and
you
shift
into
gear
and release the
clutch,
the
engine
stops.
—
Take the
weight
off the side stand and
swing
it back
up
with
your
foot
as
far
as
it will
go.
Switching
off ABS
KTM recommends
riding
with
ABS
at
all times.
However,
situa-
tions
may
arise in which ABS is
not
advantageous.
Condition
Vehicle
stationary, engine running.
—
Press button
@
for 3
-
5 seconds.
&
The
ABS
warning
lamp
starts
flashing;
ABS
is
deactivated.
Danger
Danger
of
poisoning
Exhaust
gases
are
toxic
and
inhaling
them
may
result
in
unconsciousness
and
death.
-
Always
make
sure
there
is
sufficient
ventilation
when
running
the
engine.
-
Use
an
effective
exhaust
extraction
system
when
starting
or
running
the
engine
in
an
enclosed
space.
e
Info
Press the
starter
for
a
maximum of 5 seconds. Wait for
a
least 5 seconds before
trying again.
Condition
14

Turn
the
emergency
OFF switch
to
the
position
©.
Shift
gear
to
neutral.
Switch
on
the
ignition.
Press the electric
starter
button ®.
(N)
()
B00103-10
e
Info
Do not
open
the
throttle.
15

e
Info
The
hydraulic
compression
damping
determines
the fork
suspension
behavior.
—
Turn the white
adjusting
screw
0
all the
way
clockwise.
Info
e
|
Adjusting
screw
@
is located
at
the
upper
end of the
left fork
leg.
The
compression
damping
is
located in
the
left fork
leg
COMP
(white
adjusting
screw).
The rebound
damp-
ing
is located in the
right
fork
leg
REB
(red
adjusting
screw).
BO1949-10
—
Turn counterclockwise
by
the
number of clicks
corresponding
to
the fork
type.
Guideline
Compression damping
Comfort 20
clicks
Standard 15 clicks
Sport
10
clicks
Full
payload
10
clicks
e
Info
Turn clockwise
to
increase
damping;
turn
counterclock-
wise
to
reduce
damping.
e
Info
The
hydraulic
rebound
damping
determines the fork rebound behavior.
Turn the red
adjusting
screw
oO
all the
way
clockwise.
e
Info
I
Adjusting
screw
eb
is
located
at
the
upper
end
of
the
right
fork
leg.
The rebound
damping
is located
in
the
right
fork
leg
REB
(red
adjusting
screw).
The
compression
damping is
located in the left fork
leg
COMP
(white
adjusting
screw).
BO1949-11
Turn counterclockwise
by
the
number of clicks
corresponding
to the fork
type.
16

Guideline
Rebound
damping
Comfort 20 clicks
Standard 15 clicks
Sport
10 clicks
Full
payload
10 clicks
e
Info
Turn clockwise
to
increase
damping;
turn counterclock-
wise
to
reduce
damping.
Preparatory
work
—
Lean
the
motorcycle
on
the
side
stand.
Main
work
—
Loosen
bleeder
screws
0.
~
Any
excess
pressure escapes
from the interior of the fork.
—
Tighten
the bleeder
screws.
e
=
Info
Carry
out
this action
on
both
fork
legs.
Preparatory
work
—
Raise
the
motorcycle
with
a
lift
stand.
(<9
p.
12)
—
Loosen the fork
protection.
(©"
p.
18)
Main
work
—
Push dust boots
@
of both fork
legs
downward.
e
Info
i
The dust boots
remove
dust
and
coarse
dirt
particles
from the
inside fork tubes.
Over
time,
dirt
can
pene-
trate
behind
the
dust
boots.
If
this dirt is not
removed,
the oil seals behind the dust boots
can
start to
leak.
$00642-10
Warning
Danger
of
accidents
Oil
or
grease
on
the brake
discs
reduces the
braking
effect.
—
Always
keep
the brake
discs
free of oil and
grease.
—
Clean
the
brake discs
with brake
cleaner when
nec-
essary.
-
Clean
and
oil
the dust
boots and inner fork tube of
both fork
legs.
Universal oil
spray
(—
p.
281)
17

—
Press the dust boots back into their
normal
position.
—
Remove
excess
oil.
Finishing
work
—
Position the fork
protector.
('—
p.
18)
-
Remove
the
motorcycle
from the
lift
stand.
(“>
p.
12)
4
-
Remove
screws
@
and
take off
clamp.
—
Remove
screws
Qe
on
left fork
leg.
Push the fork
protection
downwards.
—
Remove
screws
©
on
the
right
fork
leg.
Push the fork
protec-
tor downward.
€
—
Position the fork
protector
on
the
left fork
leg.
Mount
and
tighten
screws
@.
Guideline
Remaining
screws,
M6 10 Nm
(7.4
Ibf
ft)
chassis
—
Position
the brake
line,
wiring
harness,
and
clamp.
Mount
and
tighten
screws
@.
—
Position
the
fork
protector
on
the
right
fork
leg.
Mount
and
tighten
screws
©.
Guideline
Remaining
screws,
M6 10 Nm
(7.4
Ibf
ft)
chassis
Preparatory
work
—
Raise
the
motorcycle
with
a
lift
stand.
(~~
p.
12)
—
Clamp
down the
rear
of the vehicle.
Main
work
-
Remove
screws
@.
—
Remove the cable
tie(s).
—
Press back the
brake
linings
with
a
light
lateral
tilting
of
the
brake
caliper
on
the
brake disc.
Carefully
pull
the
brake
caliper
backward from the brake disc.
GOO724-10
18