KTM 690 Enduro R EU 2014 Manual

SETUP INSTRUCTIONS 2014
690 Enduro R EU
690 Enduro R AU/GB
690 Enduro R US
Art. no. 3213154en

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.
© 2014 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 to the starter relay.
B00248-10
–Remove the rear fairing. ( p. 9)
–Four markings can 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 .
–Fit the rear fairing. ( p. 10)
700217-01
–Mount the reflector.

2 SETUP 5
B00250-10
–Insert the rubber sleeves in the footrest bracket.
–Position the engine guard. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Operation as 2-seater
–Fit the rear footrest bracket. ( p. 10)
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. 11)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
–Set kilometers or miles. ( p. 12)

3 WORK 6
3.1 Removing the seat
B01948-10
–Pull on strap and raise the rear of the seat at the same time.
–Pull back the seat and lift it off.
3.2 Mounting the seat
B01953-10
–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 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 .
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing .
–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. 12)
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)
B01974-10
Main work
–Remove battery cover .
–Pull the EFI control unit off of the holder and set it to one side.

3 WORK 8
B01975-10
–Disconnect negative cable of the battery.
–Take off the positive terminal cover and disconnect the positive cable from the
battery.
–Remove screws .
–Pull retaining bracket of the battery forward and remove it.
–Lift the battery up and out.
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.
3.5 Installing the battery
B01975-11
Main work
–Insert the battery into the battery compartment with the terminals facing rearward.
Battery (YTZ10S)
–Position retaining bracket and mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the positive cable and mount and tighten the screw.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position positive terminal cover .
–Position negative cable and mount and tighten the screw.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
B01976-10
–Position EFI control unit .
–Mount battery cover .
Finishing work
–Mount the seat. ( p. 6)
–Set the clock. ( p. 12)
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.

3 WORK 9
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 and 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.
3.8 Removing rear fairing
Preparatory work
–Remove the seat. ( p. 6)
100311-10
Main work
–Remove screws .
100314-10
–Remove screws .
–Open the filler cap. ( p. 8)
–Take off the rear fairing.
–Close the filler cap. ( p. 9)

3 WORK 10
3.9 Fitting rear fairing
100315-10
–Position the license plate holder and cable harness.
–Open the filler cap. ( p. 8)
–Position the rear fairing and grab handles as shown in the figure. Fit and
slightly tighten the screws of the grab handles.
–Close the filler cap. ( p. 9)
–Fit and tighten the screws on the rear fairing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
100314-10
–Mount and tighten screws .
–Tighten the screws of the grab handles.
Guideline
Screw, handrail M8 20 Nm
(14.8 lbf ft)
–Mount the seat. ( p. 6)
3.10 Fitting the rear footrest bracket
Info
The operations are the same for the left and right sides.
100316-10
–Position the footrest bracket . Mount and tighten screws .
Guideline
Screw, rear footrest bracket M8x16 25 Nm
(18.4 lbf ft)
3.11 Mounting the rubber strap for the side stand
0
0
11
B00246-10
–Drill a hole of the specified size at marking .
Guideline
Hole diameter for rubber strap 8.0 mm (0.315 in)
Info
A marking is found on the inside of the left heel protector.
–Mount the rubber strap.
3.12 Fitting heel protector
Info
The operations are the same for the left and right sides.

3 WORK 11
100317-10
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.
–Position the heel protector . Mount and tighten screws .
Guideline
Screw, heel protector M8x12 5 Nm
(3.7 lbf ft)
Loctite®243™
3.13 Refueling
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.
Note
Material damage Premature clogging of the fuel filter.
–In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system.
–Only refuel with clean fuel that meets the specified standards.
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.
400405-10
–Switch off the engine.
–Open the filler cap. ( p. 8)
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement 20 mm (0.79 in)
Total fuel tank
capacity, approx.
12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 15)
–Close the filler cap. ( p. 9)
401429-10
–Press the SET button for two seconds.
The fuel level warning lamp switches off. TRIP F is set to 0.0 and the dis-
play returns to the previous display mode.
Info
If you do not press the SET button , the reset takes place automatically
after approx. three minutes.

3 WORK 12
3.14 Setting the clock
Condition
The motorcycle is stationary.
401444-01
–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.
–Press the MODE button to set the hour.
–Press the SET button to set the minute.
–Keep the MODE button and the SET button pressed simultaneously.
The time is set.
3.15 Setting kilometers or miles
Info
If you change the unit, the value is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is stationary.
400839-01
–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.
Guideline
Activation duration of MODE button 10 s

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 13
Screw, chain guard EJOT 2 Nm (1.5 lbf ft) –
Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) –
Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) –
Screw, side cover on spoiler EJOT 1 Nm (0.7 lbf ft) –
Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) –
Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) –
Fitting, side stand switch M4 2 Nm (1.5 lbf ft) –
Spoke nipple, front wheel M4.5 3… 6 Nm (2.2… 4.4 lbf ft) –
Bolt, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite®243™
Remaining nuts, chassis M5 4 Nm (3 lbf ft) –
Remaining screws, chassis M5 4 Nm (3 lbf ft) –
Screw, brake line holder on swingarm M5 4 Nm (3 lbf ft) –
Screw, cable on starter motor M5 3 Nm (2.2 lbf ft) –
Screw, electrical holder M5 3 Nm (2.2 lbf ft) –
Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) Loctite®243™
Screw, fuel hose clamp on fuel tank M5 5 Nm (3.7 lbf ft) –
Screw, fuel level sensor M5 3 Nm (2.2 lbf ft) –
Screw, fuel pump M5 4 Nm (3 lbf ft) –
Screw, fuel tank closure flange M5 2.5 Nm (1.84 lbf ft) –
Screw, headlight mask M5 5 Nm (3.7 lbf ft) –
Screw, pressure regulator M5 4 Nm (3 lbf ft) –
Screw, throttle grip M5 3.5 Nm (2.58 lbf ft) –
Spoke nipple, rear wheel M5 3… 6 Nm (2.2… 4.4 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws on fuel tank M6 5 Nm (3.7 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw connection, foot brake cylinder M6 10 Nm (7.4 lbf ft) –
Screw, ABS control unit M6 5 Nm (3.7 lbf ft) –
Screw, air filter box top M6 2 Nm (1.5 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, brake fluid reservoir of rear
brake
M6 5 Nm (3.7 lbf ft) –
Screw, chain guard M6 2 Nm (1.5 lbf ft) Loctite®243™
Screw, chain guide M6 8 Nm (5.9 lbf ft) –
Screw, chain sliding guard M6 8 Nm (5.9 lbf ft) Loctite®243™
Screw, fan hood M6 4 Nm (3 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, ignition lock M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, lower radiator bracket M6 8 Nm (5.9 lbf ft) –
Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, radiator guard M6 8 Nm (5.9 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, seat lock M6 5 Nm (3.7 lbf ft) –
Screw, side cover M6 5 Nm (3.7 lbf ft) –
Screw, upper radiator bracket M6 10 Nm (7.4 lbf ft) –
Screw, voltage regulator M6 8 Nm (5.9 lbf ft) –
Screw, wheel speed sensor M6 6 Nm (4.4 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701™
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 14
Screw, connection lever on frame M8 30 Nm (22.1 lbf ft) Loctite®243™
Screw, foot brake lever M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) –
Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) –
Screw, fuel tank, bottom M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, fuel tank, top M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, handrail M8 20 Nm (14.8 lbf ft) –
Screw, heel protector M8x12 5 Nm (3.7 lbf ft) Loctite®243™
Screw, license plate holder, top M8 20 Nm (14.8 lbf ft) –
Screw, main silencer clamp M8 12 Nm (8.9 lbf ft) Copper paste
Screw, main silencer holder M8 25 Nm (18.4 lbf ft) –
Screw, main silencer holder on fuel
tank
M8 25 Nm (18.4 lbf ft) –
Screw, rear footrest bracket M8x16 25 Nm (18.4 lbf ft) –
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, spring holder on side stand
bracket
M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite®243™
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Screw, engine bearer on frame M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite®243™
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Banjo bolt, brake line M10x1 20 Nm (14.8 lbf ft) –
Screw, swingarm pivot M12 80 Nm (59 lbf ft) –
Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Copper paste
Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) –
Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft) –
Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite®243™
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) –

5 SUBSTANCES 15
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

*3213154en*
3213154en
01/2014
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM