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KTM 690 Enduro R EU 2012 User Manual

KTM 690 Enduro R EU 2012
234 pages
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REPAIR MANUAL 2012
690 Enduro R EU
690 Enduro R AUS/UK
690 Enduro R USA
Art. no. 3206125en

Table of Contents

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KTM 690 Enduro R EU 2012 Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke
Displacement690 cc
Bore x Stroke102 mm x 84.5 mm
StarterElectric starter
Transmission6-speed
CoolingLiquid cooled
LubricationForced oil lubrication with 2 oil pumps
IgnitionContactless, controlled, fully electronic ignition system with digital ignition timing adjustment
Front SuspensionWP USD Ø 48 mm
Rear BrakeBrembo single-piston floating caliper, brake disc Ø 240 mm
ABSOptional
Front Wheel1.85 x 21"
Rear Wheel2.50 x 18"
Front Tire90/90-21"
Rear Tire140/80-18"
Seat Height910 mm
Ground Clearance280 mm
Fuel Capacity12 liters
Power49 kW (67 hp) @ 7, 500 rpm
Torque68 Nm
Fuel SystemKeihin EFI (Electronic Fuel Injection)
Clutchhydraulically operated
FrameChromium-Molybdenum steel trellis frame, powder coated
Rear SuspensionWP shock absorber with Pro-Lever linkage
Front BrakeBrembo four-piston radial caliper, brake disc Ø 300 mm
Wheelbase1504 mm
Dry Weight138.5 kg

Summary

1 MEANS OF REPRESENTATION

1.1 Symbols used

Explains the meaning of specific symbols used in the manual.

1.2 Formats used

Explains typographical formats used in the document.

2 SAFETY ADVICE

2.2 Safety advice

General safety instructions for operating the vehicle.

2.3 Degrees of risk and symbols

Defines risk levels and associated symbols for warnings.

2.4 Work rules

Outlines general rules and precautions for performing repair work.

3 IMPORTANT NOTES

3.1 Guarantee, warranty

Notes regarding warranty claims and authorized service.

3.2 Operating and auxiliary substances

Guidelines for using operating and auxiliary substances.

3.3 Spare parts, accessories

Recommendations for using approved spare parts and accessories.

4 SERIAL NUMBERS

4.1 Chassis number

Location and identification of the chassis number.

4.3 Engine number

Location and identification of the engine number.

4.6 Shock absorber part number

Location of the shock absorber part number.

5 MOTORCYCLE

5.1 Raising the motorcycle with the lift stand

Procedure for safely raising the motorcycle using a lift stand.

5.5 Starting

Instructions and safety precautions for starting the engine.

6 FORK, TRIPLE CLAMP

6.1 Adjusting the compression damping of the fork

How to adjust the fork's compression damping settings.

6.7 Removing the fork legs

Detailed steps for removing the front fork legs.

6.10 Disassembling the fork legs

Step-by-step guide for disassembling fork legs.

6.17 Checking the steering head bearing play

How to check for play in the steering head bearing.

7 HANDLEBAR, CONTROLS

7.2 Adjusting handlebar position

Steps for adjusting the handlebar position for comfort.

7.4 Checking the play in the throttle cable

How to check for correct free play in the throttle cable.

8 FRAME

8.1 Removing the engine guard

Steps for removing the engine guard.

9 SHOCK ABSORBER, SWINGARM

9.1 Adjusting the high-speed compression damping of the shock absorber

How to adjust high-speed compression damping on the shock absorber.

9.7 Adjusting the spring preload of the shock absorber

How to adjust the shock absorber's spring preload.

9.9 Removing the shock absorber

Step-by-step guide for removing the rear shock absorber.

9.13 Dismantling the damper

Steps for dismantling the shock absorber damper.

10 EXHAUST

10.1 Removing the manifold

Steps for removing the exhaust manifold.

10.3 Removing the main silencer

Procedure for removing the main exhaust silencer.

11 AIR FILTER

11.1 Removing the air filter

Steps for removing the air filter element.

11.3 Removing the air filter box

Procedure for removing the air filter box assembly.

12 FUEL TANK, SEAT, TRIM

12.3 Removing the seat

Procedure for removing the motorcycle seat.

12.7 Checking the fuel pressure

Procedure for checking the fuel system pressure.

12.8 Changing the fuel filter

Steps for changing the fuel filter.

13 WHEELS

13.1 Checking the tire air pressure

How to check and set tire air pressure for different conditions.

13.3 Checking the brake discs

Procedures for checking brake disc thickness and condition.

13.6 Front wheel

Procedures related to the front wheel assembly.

13.7 Rear wheel

Procedures related to the rear wheel assembly.

13.7.5 Checking the chain tension

How to check and measure the chain tension.

13.7.6 Adjusting the chain tension

Steps for adjusting the drive chain tension.

14 WIRING HARNESS, BATTERY

14.1 Removing the battery

Steps for safely removing the motorcycle battery.

14.5 Recharging the battery

Instructions and safety precautions for recharging the battery.

14.7 Changing the main fuse

Procedure for replacing the main fuse.

14.9 Adjusting the engine characteristic

How to adjust engine performance modes.

15 BRAKE SYSTEM

15.1 Checking the front brake linings

How to check front brake lining thickness and condition.

15.5 Uninstalling the front brake fluid

Procedure for changing the front brake fluid.

15.8 Checking the rear brake linings

How to check rear brake lining thickness and condition.

15.12 Checking rear brake fluid level

How to check the rear brake fluid level.

16 LIGHTING SYSTEM, INSTRUMENTS

16.1 Combination instrument

Settings and functions of the combination instrument display.

16.3 Adjusting the headlight range

Procedure for adjusting the headlight beam range.

16.7 Changing the headlight bulb

Procedure for replacing the main headlight bulb.

17 ENGINE

17.1 Removing the engine

Detailed steps for removing the engine from the motorcycle.

17.2 Installing the engine

Detailed steps for installing the engine into the motorcycle.

17.3 Engine disassembly

Overview of engine disassembly procedures.

17.4 Work on individual parts

Detailed procedures for working on specific engine components.

17.5 Engine assembly

Overview of engine reassembly procedures.

18 CLUTCH

18.1 Checking/rectifying the fluid level of the hydraulic clutch

How to check and adjust hydraulic clutch fluid level.

18.2 Changing the hydraulic clutch fluid

Procedure for changing the hydraulic clutch fluid.

19 WATER PUMP, COOLING SYSTEM

19.1 Draining the coolant

Steps for draining the engine coolant.

19.2 Filling/bleeding the cooling system

Procedure for filling and bleeding the cooling system.

19.3 Checking the antifreeze and coolant level

How to check coolant antifreeze and level.

20 LUBRICATION SYSTEM

20.1 Oil circuit

Diagram and explanation of the engine oil lubrication circuit.

20.2 Checking the engine oil level

How to check the engine oil level.

20.3 Checking the engine oil pressure

Procedure for checking engine oil pressure.

20.4 Changing the engine oil and filter, cleaning the oil screens

Steps for changing engine oil and filter, cleaning oil screens.

20.6 Removing the oil filter

Steps for removing and replacing the engine oil filter.

21 IGNITION SYSTEM

21.1 Alternator - checking the stator winding

How to check the alternator stator winding resistance and for short circuits.

21.2 Checking the spark plug connector

How to check the spark plug connector resistance.

21.3 Ignition coil - checking the secondary winding

How to check the ignition coil's secondary winding resistance.

22 TECHNICAL DATA

22.1 Engine

Specifications for the engine, including design, dimensions, and lubrication.

22.2 Engine tolerance, wear limits

Technical tolerances and wear limits for engine components.

22.3 Engine tightening torques

A table listing engine component tightening torques.

22.5 Chassis

Specifications for the chassis, fork, shock absorber, and brakes.

22.8 Fork

Technical data for the front fork, including damping and oil.

22.9 Shock absorber

Technical data for the shock absorber, including damping and gas pressure.

22.10 Chassis tightening torques

Table of tightening torques for chassis components.

23 CLEANING/PROTECTIVE TREATMENT

23.1 Cleaning the motorcycle

Step-by-step guide for cleaning the motorcycle.

23.2 Checks and maintenance steps for winter operation

Maintenance procedures for preparing the motorcycle for winter storage.

24 STORAGE

24.1 Storage

Instructions for storing the motorcycle for extended periods.

24.2 Preparing for use after storage

Steps to take the motorcycle out of storage and prepare it for use.

25 SERVICE SCHEDULE

25.1 Service schedule

Maintenance schedule outlining intervals and tasks.

26 WIRING DIAGRAM

26.1 Page 01 of 10

First part of the motorcycle's electrical wiring diagram.

26.2 Page 02 of 10

Second part of the motorcycle's electrical wiring diagram.

26.3 Page 03 of 10

Third part of the motorcycle's electrical wiring diagram.

26.4 Page 04 of 10

Fourth part of the motorcycle's electrical wiring diagram.

26.5 Page 05 of 10

Fifth part of the motorcycle's electrical wiring diagram.

26.6 Page 06 of 10

Sixth part of the motorcycle's electrical wiring diagram.

26.7 Page 07 of 10

Seventh part of the motorcycle's electrical wiring diagram.

26.8 Page 08 of 10

Eighth part of the motorcycle's electrical wiring diagram.

26.9 Page 09 of 10

Ninth part of the motorcycle's electrical wiring diagram.

26.10 Page 10 of 10

Tenth part of the motorcycle's electrical wiring diagram.

27 SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Specifications and recommendations for brake fluid types.

Coolant

Specifications and recommendations for coolant types.

Engine oil (SAE 10W/60) (00062010035)

Specifications for SAE 10W/60 engine oil.

Fork oil (SAE 4) (48601166S1)

Specifications for SAE 4 fork oil.

Super unleaded (ROZ 95/RON 95/PON 91)

Fuel grade specifications and warnings.

28 AUXILIARY SUBSTANCES

Chain cleaner

Recommended chain cleaner products.

Cleaning and preserving materials for metal, rubber and plastic

Recommended cleaning and preserving materials.

Fuel additive

Recommended fuel additive products.

Long-life grease

Recommended long-life grease products.

Lubricant (T158)

Recommended lubricant T158.

Lubricant (T511)

Recommended lubricant T511.

Lubricant (T159)

Recommended lubricant T159.

Motorcycle cleaner

Recommended motorcycle cleaner products.

29 SPECIAL TOOLS

Bearing puller

Identification of bearing puller tool.

Bleeding device

Identification of bleeding device tool.

Engine assembly stand

Identification of engine assembly stand tool.

Work stand

Identification of work stand tool.

Pressing device for crankshaft, complete

Identification of pressing device for crankshaft.

Hook wrench

Identification of hook wrench tool.

30 STANDARDS

JASO T903 MA

Explanation of the JASO T903 MA standard for motorcycle oils.

SAE

Explanation of SAE viscosity classifications for oils.

25 SERVICE SCHEDULE

25.1 Service schedule

Maintenance schedule outlining intervals and tasks.

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