KTM 690 Enduro R 2015 Owner's manual

Category
Motorcycles
Type
Owner's manual
OWNER'S MANUAL 2015
690 Enduro R US
Art. no. 3213264en
DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase 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 a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.
Chassis number ( p. 26) Dealer's stamp
Engine number ( p. 27)
Key number ( p. 27)
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to develop-
ments in design cannot be ruled out completely.
All specifications are non-binding. KTM Motorrad AG specifically reserves the right to modify or delete technical specifications, prices, col-
ors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local condi-
tions, 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, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to
the regular scope of supply.
© 2014 KTM Motorrad 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.
DEAR KTM CUSTOMER 2
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: TÃœV Management Service
KTM Motorrad AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
1.1 Symbols used ...................................................... 7
1.2 Formats used....................................................... 7
2 SAFETY ADVICE.............................................................. 8
2.1 Use definition - intended use ................................ 8
2.2 Safety advice....................................................... 8
2.3 Degrees of risk and symbols.................................. 9
2.4 Overview of labels .............................................. 10
2.5 Reporting safety defects ..................................... 15
2.6 Noise emission warranty ..................................... 15
2.7 Operating noise warning ..................................... 16
2.8 Consumer rights................................................. 16
2.9 Tampering warning............................................. 16
2.10 Safe operation ................................................... 17
2.11 Protective clothing ............................................. 18
2.12 Work rules......................................................... 18
2.13 Environment...................................................... 18
2.14 Owner's Manual ................................................. 19
3 IMPORTANT NOTES...................................................... 20
3.1 Guarantee, warranty ........................................... 20
3.2 Operating and auxiliary substances...................... 20
3.3 Spare parts, accessories ..................................... 20
3.4 Service ............................................................. 20
3.5 Figures ............................................................. 21
3.6 Customer service................................................ 21
4 VIEW OF VEHICLE ........................................................ 22
4.1 View of vehicle, front left side (example) .............. 22
4.2 View of vehicle, rear right side (example).............. 24
5 SERIAL NUMBERS ....................................................... 26
5.1 Chassis number ................................................. 26
5.2 Type label ......................................................... 26
5.3 Key number....................................................... 27
5.4 Engine number .................................................. 27
5.5 Fork part number ............................................... 28
5.6 Shock absorber part number ............................... 28
6 CONTROLS................................................................... 29
6.1 Clutch lever....................................................... 29
6.2 Hand brake lever................................................ 29
6.3 Throttle grip ...................................................... 30
6.4 Horn button....................................................... 30
6.5 Light switch ...................................................... 31
6.6 Turn signal switch.............................................. 31
6.7 Emergency OFF switch ....................................... 32
6.8 Electric starter button......................................... 32
6.9 Ignition/steering lock.......................................... 33
6.10 Combination instrument ..................................... 33
6.10.1 Combination instrument overview .................... 33
6.10.2 Function buttons ........................................... 34
6.10.3 Tachometer................................................... 34
6.10.4 Indicator lamps ............................................. 35
6.10.5 Display ......................................................... 36
6.10.6 Speed display................................................ 37
6.10.7 Setting kilometers or miles ............................. 37
6.10.8 Time............................................................. 38
6.10.9 Setting the clock ........................................... 38
6.10.10 ODO display .................................................. 39
6.10.11 Setting/resetting display TRIP 1 ...................... 39
TABLE OF CONTENTS 4
6.10.12 Setting/resetting display TRIP 2 ...................... 40
6.10.13 TRIP F display............................................... 41
6.10.14 GEAr display ................................................. 41
6.10.15 Coolant temperature indicator ......................... 42
6.11 Opening the filler cap......................................... 42
6.12 Closing filler cap................................................ 43
6.13 Seat release ...................................................... 44
6.14 Handrails .......................................................... 44
6.15 Passenger footrests ............................................ 45
6.16 Shift lever ......................................................... 45
6.17 Foot brake lever ................................................. 46
6.18 Side stand......................................................... 47
7 PREPARING FOR USE................................................... 48
7.1 Advice on first use ............................................. 48
7.2 Running in the engine ........................................ 49
7.3 Loading the vehicle............................................ 50
8 RIDING INSTRUCTIONS................................................ 52
8.1 Performing checks and vehicle care when
preparing for use................................................ 52
8.2 Starting............................................................. 53
8.3 Starting off........................................................ 55
8.4 Shifting, riding .................................................. 55
8.5 Braking............................................................. 58
8.6 Stopping, parking............................................... 60
8.7 Transport .......................................................... 61
8.8 Refueling .......................................................... 62
9 SERVICE SCHEDULE .................................................... 65
9.1 Service schedule................................................ 65
10 TUNING THE CHASSIS ................................................. 68
10.1 Fork/shock absorber ........................................... 68
10.2 Adjusting the compression damping of the fork..... 68
10.3 Adjusting the rebound damping of the fork ........... 69
10.4 Compression damping of the shock absorber......... 70
10.5 Adjusting the low-speed compression damping of
the shock absorber............................................. 70
10.6 Adjusting the high-speed compression damping
of the shock absorber ......................................... 71
10.7 Adjusting the rebound damping of the shock
absorber............................................................ 72
10.8 Measuring the unloaded rear wheel sag ................ 73
10.9 Checking the static sag of the shock absorber....... 74
10.10 Checking the riding sag of the shock absorber....... 75
10.11 Adjusting the spring preload of the shock
absorber ........................................................ 75
10.12 Adjusting the riding sag .................................. 77
10.13 Handlebar position............................................. 78
10.14 Adjusting handlebar position ........................... 78
11 SERVICE WORK ON THE CHASSIS................................. 80
11.1 Raising the motorcycle with the lift stand............. 80
11.2 Removing the motorcycle from the lift stand......... 80
11.3 Cleaning the dust boots of the fork legs................ 81
11.4 Loosening the fork protection .............................. 82
11.5 Positioning the fork protector .............................. 83
11.6 Checking the steering head bearing play............... 83
11.7 Adjusting the play of the steering head
bearing .......................................................... 84
11.8 Removing the seat ............................................. 86
11.9 Mounting the seat .............................................. 86
TABLE OF CONTENTS 5
11.10 Removing the air filter .................................... 87
11.11 Installing the air filter ..................................... 88
11.12 Checking the chain for dirt.................................. 89
11.13 Cleaning the chain ............................................. 89
11.14 Checking the chain tension................................. 90
11.15 Adjusting the chain tension................................. 92
11.16 Checking the chain, rear sprocket, engine
sprocket, and chain guide................................... 93
11.17 Adjusting chain guide ..................................... 98
11.18 Adjusting basic position of clutch lever ................ 99
11.19 Checking/rectifying the fluid level of the
hydraulic clutch................................................. 99
11.20 Removing the engine guard............................... 100
11.21 Installing the engine guard ............................... 101
12 BRAKE SYSTEM ......................................................... 102
12.1 ABS/antilock brake system................................ 102
12.2 Adjusting the basic position of the hand brake
lever ............................................................... 103
12.3 Checking the brake discs .................................. 104
12.4 Checking brake fluid level of front brake ............ 105
12.5 Topping up brake fluid of front brake. ............ 106
12.6 Checking the front brake linings ........................ 107
12.7 Changing the front brake linings .................... 108
12.8 Checking the free travel of foot brake lever ......... 111
12.9 Adjusting the basic position of the foot brake
lever ............................................................ 112
12.10 Checking rear brake fluid level .......................... 113
12.11 Adding rear brake fluid ................................. 114
12.12 Checking the rear brake linings ......................... 116
12.13 Changing the rear brake linings ...................... 116
13 WHEELS, TIRES ......................................................... 120
13.1 Removing the front wheel .............................. 120
13.2 Installing the front wheel .............................. 121
13.3 Removing rear wheel ..................................... 123
13.4 Installing the rear wheel ................................ 124
13.5 Checking the rear hub rubber dampers ........... 126
13.6 Checking the tire condition ............................... 128
13.7 Checking the tire air pressure............................ 129
13.8 Checking the spoke tension............................... 130
14 ELECTRICAL SYSTEM ................................................. 132
14.1 Removing the battery .................................... 132
14.2 Installing the battery ..................................... 134
14.3 Recharging the battery .................................. 136
14.4 Changing the main fuse.................................... 139
14.5 Changing the ABS fuses ................................... 140
14.6 Changing fuses of individual power consumers.... 142
14.7 Removing the headlight mask with the
headlight......................................................... 144
14.8 Installing the headlight mask with the
headlight......................................................... 145
14.9 Changing the headlight bulb ............................. 146
14.10 Changing the parking light bulb......................... 148
14.11 Changing the turn signal bulb ........................... 149
14.12 Checking the headlight setting .......................... 150
14.13 Adjusting the headlight range............................ 151
15 COOLING SYSTEM ...................................................... 152
15.1 Cooling system ................................................ 152
15.2 Checking the antifreeze and coolant level........... 152
15.3 Checking the coolant level ................................ 154
TABLE OF CONTENTS 6
15.4 Draining the coolant ..................................... 155
15.5 Filling/bleeding the cooling system ................. 156
16 TUNING THE ENGINE................................................. 159
16.1 Adjusting the engine characteristic .................... 159
16.2 Checking the basic position of the shift lever ...... 160
16.3 Adjusting the basic position of the shift
lever ............................................................ 160
17 SERVICE WORK ON THE ENGINE ................................ 162
17.1 Checking the engine oil level............................. 162
17.2 Changing the engine oil and filter, cleaning the
oil screens ................................................... 163
17.3 Draining the engine oil .................................. 163
17.4 Removing the oil filter .................................. 164
17.5 Cleaning the oil screens ................................ 166
17.6 Installing the oil filter ................................... 168
17.7 Filling up with engine oil ............................... 168
17.8 Adding engine oil............................................. 169
18 CLEANING, CARE ....................................................... 171
18.1 Cleaning the motorcycle ................................... 171
18.2 Checks and maintenance steps for winter
operation......................................................... 173
19 STORAGE................................................................... 175
19.1 Storage ........................................................... 175
19.2 Preparing for use after storage........................... 176
20 TROUBLESHOOTING .................................................. 177
21 BLINK CODE .............................................................. 180
22 TECHNICAL DATA....................................................... 187
22.1 Engine ............................................................ 187
22.2 Engine tightening torques ................................. 188
22.3 Capacities ....................................................... 191
22.3.1 Engine oil ................................................... 191
22.3.2 Coolant....................................................... 192
22.3.3 Fuel ........................................................... 192
22.4 Chassis ........................................................... 192
22.5 Electrical system.............................................. 194
22.6 Tires............................................................... 194
22.7 Fork................................................................ 195
22.8 Shock absorber................................................ 196
22.9 Chassis tightening torques ................................ 197
23 SUBSTANCES ............................................................ 201
24 AUXILIARY SUBSTANCES ........................................... 204
25 STANDARDS .............................................................. 206
INDEX ............................................................................... 207
1 MEANS OF REPRESENTATION 7
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).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally
cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brandâ„¢ Identifies a brand available on the open market.
2 SAFETY ADVICE 8
2.1 Use definition - intended use
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 only authorized for operation on public roads in the homologated version.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instruc-
tions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2 SAFETY ADVICE 9
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
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
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2 SAFETY ADVICE 10
2.4 Overview of labels
B01985-10
2 SAFETY ADVICE 11
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, putting into operation
8 Information on tires
C00875-01
Type label, Canada
2 SAFETY ADVICE 12
C00876-01
Type label, USA
C00877-01
Information, emission control
2 SAFETY ADVICE 13
C00878-01
Information, noise emission
C00879-01
Information, suspension setting
2 SAFETY ADVICE 14
100338-01
Information, chain tension
700210-01
Information, putting into operation
2 SAFETY ADVICE 15
B01344-01
Information on tires
2.5 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 multiple 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 remedy 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.
2.6 Noise emission warranty
KTM Motorrad 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: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
2 SAFETY ADVICE 16
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
2.7 Operating noise warning
This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use.
Otherwise, the owner may become subject to penalties under the applicable ordinances.
2.8 Consumer rights
Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Different rights may apply, according to national or regional legislation.
2.9 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur-
chaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
2 SAFETY ADVICE 17
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufac-
turer.
2.10 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE 18
2.11 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.12 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe-
ses. E.g.: bearing puller (15112017000)
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.
In some instances, a thread locker (e.g. Loctite
®
) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.13 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle
sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that per-
tain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
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KTM 690 Enduro R 2015 Owner's manual

Category
Motorcycles
Type
Owner's manual

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