KTM 690 Enduro R User manual

OWNER'S MANUAL 2009
690 Enduro R USA
ART. NO. 3211360en

DEAR KTM CUSTOMER 1
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
enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 24) Dealer's stamp
Engine number ( p. 25)
Key number ( p. 25)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design of our motorcycles cannot, however, be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG 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 illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
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.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 3
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT NOTES............................................................... 8
Overview of warning labels................................................. 12
VIEW OF VEHICLE................................................................ 20
View of vehicle, front left side............................................ 20
View of vehicle, rear right .................................................. 22
LOCATION OF SERIAL NUMBERS ......................................... 24
Chassis number................................................................ 24
Type label........................................................................ 24
Key number ..................................................................... 25
Engine number................................................................. 25
Fork part number.............................................................. 26
Shock absorber part number.............................................. 26
CONTROLS.......................................................................... 27
Clutch lever ..................................................................... 27
Hand brake lever .............................................................. 27
Light switch ..................................................................... 28
Flasher switch.................................................................. 28
Horn button ..................................................................... 29
Emergency OFF switch...................................................... 29
Electric starter button ....................................................... 30
Ignition/steering lock ........................................................ 30
Combination instrument.................................................... 31
Combination instrument - function buttons ......................... 31
Combination instrument - indicator lamps........................... 32
Combination instrument - display....................................... 33
Combination instrument - speedometer............................... 34
Setting kilometers or miles ................................................ 34
Combination instrument - time .......................................... 35
Setting the clock .............................................................. 35
Combination instrument - display ODO ............................... 36
Combination instrument - setting/resetting TRIP 1............... 36
Combination instrument - setting/resetting TRIP 2............... 37
Combination instrument - TRIP F display............................ 38
Combination instrument - coolant temperature indicator ...... 38
Opening filler cap............................................................. 39
Closing filler cap .............................................................. 39
Handrails......................................................................... 40
Seat release ..................................................................... 40
Passenger footrests........................................................... 41
Shift lever........................................................................ 41
Foot brake pedal .............................................................. 42
Side stand ....................................................................... 43
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................... 44
Advice on first use............................................................ 44
Running in the engine....................................................... 45
Loading the vehicle .......................................................... 46
RIDING INSTRUCTIONS ....................................................... 48
Checks before putting into operation .................................. 48
Starting ........................................................................... 49
Starting up ...................................................................... 50
Shifting, riding................................................................. 51
Braking ........................................................................... 54
Stopping, parking ............................................................. 55
Refueling......................................................................... 57

CONTENTS 4
SERVICE PLAN .................................................................... 59
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................ 59
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................... 61
MAINTENANCE WORK ON CHASSIS AND ENGINE................. 63
Jacking up the motorcycle................................................. 63
Removing the motorcycle from the work stand..................... 63
Fork/shock absorber.......................................................... 64
Adjusting the compression damping of the fork ................... 64
Adjusting the rebound damping of the fork.......................... 65
Compression damping of the shock absorber ....................... 66
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 66
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 68
Adjusting the rebound damping of the shock absorber.......... 69
Measuring the unloaded rear wheel sag............................... 70
Checking the static sag of the shock absorber ..................... 71
Checking the riding sag of the shock absorber ..................... 72
Adjusting the spring preload of the shock absorber x......... 72
Bleeding the fork legs ....................................................... 73
Cleaning the dust boots of the fork legs .............................. 74
Loosening the fork protection............................................. 75
Positioning the fork protection ........................................... 75
Checking the steering head bearing play x........................ 76
Adjusting the play of the steering head bearing x.............. 77
Handlebar position ........................................................... 78
Adjusting handlebar position x........................................ 78
Checking chain dirt .......................................................... 79
Cleaning the chain............................................................ 79
Checking the chain tension ............................................... 80
Adjusting the chain tension ............................................... 81
Checking rear sprocket / engine sprocket for wear ................ 83
Checking chain wear......................................................... 84
Adjusting chain guide x.................................................. 85
Checking the brake discs................................................... 85
Checking the free play of hand brake lever.......................... 86
Adjusting free travel of handbrake lever .............................. 87
Checking the front brake fluid level .................................... 88
Adding front brake fluid x............................................... 88
Checking the front brake linings......................................... 90
Changing the front brake linings x................................... 91
Checking free play of foot brake lever ................................. 94
Adjusting basic position of footbrake lever x..................... 95
Checking rear brake fluid level........................................... 96
Adding rear brake fluid x................................................ 96
Checking the rear brake linings.......................................... 98
Changing the rear brake linings x..................................... 98
Removing the front wheel x........................................... 101
Installing the front wheel x............................................ 103
Removing rear wheel x.................................................. 104
Installing the rear wheel x............................................. 105
Checking the rear hub rubber dampers x........................ 106
Checking the tire condition.............................................. 107
Checking the tire air pressure .......................................... 109
Checking spoke tension................................................... 110

CONTENTS 5
Removing the seat.......................................................... 111
Mounting the seat .......................................................... 112
Removing the battery x................................................. 112
Installing the battery x.................................................. 113
Recharging the battery x............................................... 114
Changing the main fuse .................................................. 116
Changing the fuses of power consumers............................ 118
Adjusting the engine characteristic................................... 120
Headlight mask, removing with headlight.......................... 122
Installing the headlight mask with the headlight................ 123
Changing the headlight bulb............................................ 124
Changing the parking light bulb ....................................... 125
Changing the flasher bulb ............................................... 126
Check the headlamp setting ............................................ 127
Adjusting the headlight range .......................................... 127
Removing the air filter x............................................... 128
Installing the air filter x................................................ 129
Cooling system ............................................................... 130
Checking the antifreeze and coolant level ......................... 131
Checking the coolant level............................................... 133
Draining the coolant x.................................................. 135
Filling the cooling system x........................................... 136
Adjusting basic position of clutch lever............................. 138
Checking/rectifying the fluid level of the hydraulic clutch ... 138
Checking the play in the gas Bowden cable....................... 139
Adjusting the play in the gas Bowden cable x.................. 140
Removing the engine guard ............................................. 141
Installing the engine guard .............................................. 141
Checking the engine oil level ........................................... 142
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 142
Draining the engine oil x............................................... 143
Removing the oil filter x................................................ 144
Installing the oil filter x................................................ 146
Cleaning the oil screens x............................................. 146
Filling up with engine oil x............................................ 148
Adding engine oil ........................................................... 149
TROUBLESHOOTING.......................................................... 151
FLASHING CODE ............................................................... 154
CLEANING......................................................................... 159
Cleaning motorcycle ....................................................... 159
CONSERVING FOR WINTER OPERATION ............................. 161
Conservation for winter operation ..................................... 161
STORAGE .......................................................................... 162
Storage.......................................................................... 162
Putting into operation after storage .................................. 163
TECHNICAL DATA - ENGINE............................................... 164
Capacity- engine oil ........................................................ 165
Capacity - coolant........................................................... 165
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 166
TECHNICAL DATA - CHASSIS ............................................. 169
Lighting equipment ........................................................ 170
Tires ............................................................................. 171
Capacity - fuel................................................................ 171
TECHNICAL DATA - FORK................................................... 172
TECHNICAL DATA - SHOCK ABSORBER .............................. 173
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 175
SUBSTANCES.................................................................... 178

CONTENTS 6
AUXILIARY SUBSTANCES................................................... 182
STANDARDS...................................................................... 184
INDEX ............................................................................... 185

MEANS OF REPRESENTATION 7
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).
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.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 8
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads),
but not for use on race courses.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the ser-
vice schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
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.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT NOTES 9
Spare parts, accessories
In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in
an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
–Switch off the engine and remove the ignition key.
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT NOTES 10
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. But if you use your motorcycle responsibly, you can ensure that
such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.

IMPORTANT NOTES 11

IMPORTANT NOTES 12
2.1Overview of warning labels
800103-10

IMPORTANT NOTES 13
1 Type label, Canada
2 Type label, USA
3 Information, emission control
4 Information, noise emission
5 Information, suspension setting
6 Information, chain tension
7 Information, fuel evaporation system
8 Information, putting into operation
800110-01
Type label, Canada

IMPORTANT NOTES 14
100333-01
Type label, USA
800104-10
Information, emission control

IMPORTANT NOTES 15
800105-10
Information, noise emission
100337-01
Information, suspension setting

IMPORTANT NOTES 16
100338-01
Information, chain tension
100336-01
Information, fuel evaporation system
700210-01
Information, putting into operation

IMPORTANT NOTES 17
Notes/warnings
Pay close attention to the notes/warning.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.
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 will possibly lead to light injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

IMPORTANT NOTES 18
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information
and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your
own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motor-
cycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may
order a recall and remady campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM
North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or
write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other informa-
tion about motor vehicle safety from the Hotline.
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: [phone] x 4250
www.ktmcanada.com