KTM 690 Enduro R EU 2013 Parts list manual

SETUP INSTRUCTIONS 2013
690 Enduro R EU
690 Enduro R AUS/UK
690 Enduro R USA
Art. no. 3213054en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, 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 assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
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.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
100302-01
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during assembly, leave the protective film
on the vehicle until you have finished.
–Check the vehicle for transport damage.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
100303-01
–Remove the controls from the transport holder. Remove the screws and handlebar
clamps. Remove the transport holder.
100318-10
–Remove the M8 screw from the right hand guard.
100306-10
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
100305-10
–Position the handlebar.
The mark 1of the scale on the handlebar should be centered on the handlebar
clamp.
–Position the handlebar clamps. Mount and evenly tighten the four screws.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
100307-01
–Position the controls on the left half of the handlebar. Mount the screws.

2 SETUP 4
100309-01
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
–Exactly position all controls on the handlebar. Tighten all screws.
–Fit and tighten the M8 screw of the right hand guard.
100308-01
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Pliers for footrest spring (58429083000)
–Remove the protective plastic.
–Carefully loosen and remove the tensioning belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the palette.
B00247-12
–Recharge the battery. ( p. 6)
–Connect plug 1to the starter relay.
B00248-10
–Remove the rear fairing. ( p. 9)
–Four markings 2can be seen on the underside of the rear fairing. At these posi-
tions, drill holes in three steps of the prescribed size.
Guideline
Hole diameter for grab handles 14.50 mm (0.5709 in)
B00249-10
–Remove screws 3.
–Fit the rear fairing. ( p. 9)
700217-01
–Mount the reflector.

2 SETUP 5
B00250-10
–Insert the rubber sleeves 4in the footrest bracket.
–Position the engine guard. Mount and tighten screws 5.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Operation as 2-seater
–Fit the rear footrest bracket. ( p. 9)
Operation as 1-seater (at customer request only)
–Mount the rubber strap for the side stand. ( p. 10)
Warning
Forfeiture of homologation and insurance cover The vehicle is
homologated as 2-seater. If the heel protector is fitted instead of the
footrest bracket, the vehicle no longer conforms to the homologation and
must not be operated in this form without alterations to the registration
papers.
–Set up and operate the vehicle as a 2-seater or have changes made
to the registration papers.
–Fit the heel protector. ( p. 10)
–Refuel. ( p. 10)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( p. 11)

3 WORK 6
3.1 Removing the seat
601772-10
–Pull on strap 1and raise the rear of the seat at the same time.
–Pull back the seat and lift it off.
3.2 Mounting the seat
601782-10
–Hook slot 1of the seat onto screw 2, press the rear downward and at the same time push it forward.
–Push locking pin 3into lock housing 4and push the back of the seat down until the locking pin locks in place with an audible
click.
–Finally, check that the seat is correctly mounted.
3.3 Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
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.
Info
Even when there is no load on the battery, it still loses power steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.

3 WORK 7
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 6)
–Remove the battery. ( p. 7)
100151-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing 2.
–Switch off and disconnect the charger after charging.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Finishing work
–Install the battery. ( p. 8)
–Mount the seat. ( p. 6)
–Set the clock. ( p. 11)
3.4 Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Preparatory work
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 6)
601812-10
Main work
–Disconnect the negative (minus) cable of the battery.
–Pull plug 1off upward.
–Remove screws 2.
–Pull the retaining bracket 3of the battery forward and remove it.
–Take off the positive pole cover 4.
–Disconnect the positive (plus) cable of the battery.
–Push the wiring harness to the side and pull the battery out of the battery holder.
Info
Never operate the motorcycle with a discharged battery or without a battery.
In both cases, electrical components and safety devices can be damaged.
The vehicle is therefore no longer roadworthy.

3 WORK 8
3.5 Installing the battery
601812-11
Main work
–Slide the battery into the battery holder.
Info
The battery terminals must be at the rear.
–Attach the positive cable and mount positive terminal cover 1.
–Position retaining bracket 2.
–Mount and tighten screws 3.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Plug in connector 4.
–Attach the minus cable .
Finishing work
–Mount the seat. ( p. 6)
–Set the clock. ( p. 11)
3.6 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
601770-10
–Lift the cover of filler cap 1and insert the ignition key.
–Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
The filler cap has a fuel tank breather.
3.7 Closing filler cap
601771-01
–Put the filler cap back on and turn the ignition key 90° clockwise.
–Remove the ignition key and fold down the cover.