KTM 690 Enduro R 2012 Owner's manual

Category
Motorcycles
Type
Owner's manual

This manual is also suitable for

OWNER'S MANUAL 2012
690 Enduro R USA
Art. no. 3211802en
DEAR KTM CUSTOMER 1
DEAR KTMCUSTOMER
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 at the time of going to print. Minor differences due to developments in
design cannot be ruled out completely.
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
© 2012 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: TÃœV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLE OFCONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
Overview of warning labels................................................. 12
VIEW OF VEHICLE................................................................ 22
View of vehicle, front left (example).................................... 22
View of vehicle, rear right (example) ................................... 24
SERIAL NUMBERS............................................................... 26
Chassis number................................................................ 26
Type label........................................................................ 26
Engine number................................................................. 27
Key number ..................................................................... 27
Fork part number.............................................................. 28
Shock absorber part number.............................................. 28
CONTROLS.......................................................................... 29
Clutch lever ..................................................................... 29
Hand brake lever .............................................................. 29
Throttle grip..................................................................... 30
Light switch ..................................................................... 30
Turn signal switch ............................................................ 31
Horn button ..................................................................... 31
Emergency OFF switch...................................................... 32
Electric starter button ....................................................... 32
Ignition/steering lock ........................................................ 33
Combination instrument.................................................... 33
Combination instrument - function buttons ......................... 34
Combination instrument - indicator lamps........................... 34
Combination instrument - display....................................... 35
Combination instrument - speedometer............................... 36
Setting kilometers or miles ................................................ 36
Combination instrument - time .......................................... 37
Setting the clock .............................................................. 37
Combination instrument - display ODO ............................... 38
Combination instrument - setting/resetting TRIP 1............... 38
Combination instrument - setting/resetting TRIP 2............... 39
Combination instrument - TRIP F display............................ 40
Combination instrument - coolant temperature indicator ...... 40
Opening the filler cap ....................................................... 41
Closing filler cap .............................................................. 42
Seat release ..................................................................... 42
Handrails......................................................................... 43
Passenger footrests........................................................... 43
Shift lever........................................................................ 44
Foot brake lever................................................................ 45
Side stand ....................................................................... 45
PREPARING FOR USE.......................................................... 46
Advice on first use............................................................ 46
Running in the engine....................................................... 47
Loading the vehicle .......................................................... 48
RIDING INSTRUCTIONS ....................................................... 50
Performing checks and vehicle care when preparing for
use ................................................................................. 50
Starting ........................................................................... 51
Starting off ...................................................................... 52
Shifting, riding................................................................. 52
Braking ........................................................................... 56
Stopping, parking ............................................................. 57
Refueling......................................................................... 58
TABLE OF CONTENTS 4
SERVICE SCHEDULE............................................................ 61
Service schedule .............................................................. 61
TUNING THE CHASSIS......................................................... 64
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 ................................................................. 67
Adjusting the rebound damping of the shock absorber.......... 68
Measuring the unloaded rear wheel sag............................... 69
Checking the static sag of the shock absorber ..................... 70
Checking the riding sag of the shock absorber ..................... 71
Adjusting the spring preload of the shock absorber x ......... 71
Adjusting the riding sag x ............................................... 73
Handlebar position ........................................................... 74
Adjusting handlebar position x ........................................ 74
SERVICE WORK ON THE CHASSIS........................................ 76
Raising the motorcycle with the lift stand ........................... 76
Removing the motorcycle from the lift stand ....................... 76
Bleeding the fork legs ....................................................... 77
Cleaning the dust boots of the fork legs .............................. 77
Loosening the fork protection............................................. 78
Positioning the fork protection ........................................... 79
Checking the steering head bearing play ............................. 79
Adjusting the play of the steering head bearing x .............. 80
Removing the seat ............................................................ 82
Mounting the seat ............................................................ 82
Removing the air filter x ................................................. 83
Installing the air filter x.................................................. 84
Checking the chain for dirt ................................................ 85
Cleaning the chain............................................................ 85
Checking the chain tension ............................................... 86
Adjusting the chain tension ............................................... 87
Check the chain, rear sprocket, engine sprocket and chain
guide............................................................................... 89
Adjusting chain guide x .................................................. 94
Adjusting basic position of clutch lever............................... 95
Checking/rectifying the fluid level of the hydraulic clutch ..... 95
Removing the engine guard ............................................... 96
Installing the engine guard ................................................ 97
BRAKES.............................................................................. 98
Checking the free travel of the hand brake lever .................. 98
Adjusting the free travel of the hand brake lever .................. 98
Checking the brake discs................................................... 99
Checking the front brake fluid level .................................. 100
Adding front brake fluid x ............................................. 101
Checking the front brake linings....................................... 102
Changing the front brake linings x ................................. 103
Checking the free travel of foot brake lever........................ 107
Adjusting the basic position of the foot brake lever x ....... 107
Checking rear brake fluid level......................................... 108
Adding rear brake fluid x .............................................. 109
Checking the rear brake linings........................................ 111
Changing the rear brake linings x................................... 111
TABLE OF CONTENTS 5
WHEELS, TIRES ................................................................ 115
Removing the front wheel x........................................... 115
Installing the front wheel x............................................ 116
Removing rear wheel x.................................................. 118
Installing the rear wheel x............................................. 119
Checking the rear hub rubber dampers x ........................ 120
Checking the tire condition.............................................. 122
Checking the tire air pressure .......................................... 123
Checking the spoke tension ............................................. 124
ELECTRICAL SYSTEM ........................................................ 126
Removing the battery x................................................. 126
Installing the battery x.................................................. 127
Recharging the battery x............................................... 128
Changing the main fuse .................................................. 131
Changing fuses of individual power consumers .................. 132
Removing the headlight mask with the headlight ............... 134
Installing the headlight mask with the headlight................ 136
Changing the headlight bulb............................................ 137
Changing the parking light bulb ....................................... 138
Changing the turn signal bulb.......................................... 140
Changing the tail light..................................................... 141
Checking the headlight setting......................................... 142
Adjusting the headlight range .......................................... 142
COOLING SYSTEM ............................................................. 144
Cooling system ............................................................... 144
Checking the antifreeze and coolant level ......................... 144
Checking the coolant level............................................... 146
Draining the coolant x .................................................. 148
Filling the cooling system x........................................... 149
TUNING THE ENGINE ........................................................ 152
Checking the play in the throttle cable.............................. 152
Adjusting the play in the throttle cable x ........................ 153
Adjusting the engine characteristic................................... 153
Checking the basic position of the shift lever..................... 155
Adjusting the basic position of the shift lever x ............... 155
SERVICE WORK ON THE ENGINE ....................................... 157
Checking the engine oil level ........................................... 157
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 158
Draining the engine oil x............................................... 158
Removing the oil filter x................................................ 159
Cleaning the oil screens x ............................................. 161
Installing the oil filter x ................................................ 163
Filling up with engine oil x............................................ 163
Adding engine oil ........................................................... 164
CLEANING, CARE .............................................................. 166
Cleaning the motorcycle.................................................. 166
Checks and maintenance steps for winter operation ........... 168
STORAGE .......................................................................... 169
Storage.......................................................................... 169
Preparing for use after storage ......................................... 170
TROUBLESHOOTING.......................................................... 171
BLINK CODE ..................................................................... 174
TECHNICAL DATA - ENGINE............................................... 179
Capacity - engine oil ....................................................... 180
Capacity - coolant........................................................... 180
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 181
TABLE OF CONTENTS 6
TECHNICAL DATA - CHASSIS ............................................. 184
Lighting equipment ........................................................ 185
Tires ............................................................................. 186
Capacity - fuel................................................................ 186
TECHNICAL DATA - FORK................................................... 187
TECHNICAL DATA - SHOCK ABSORBER .............................. 188
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 190
SUBSTANCES.................................................................... 194
AUXILIARY SUBSTANCES................................................... 198
STANDARDS...................................................................... 200
INDEX ............................................................................... 201
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 performed by an authorized KTM workshop! There, your motorcycle will be serviced opti-
mally by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
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.
IMPORTANT INFORMATION 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.
Service
A prerequisite for fault-free operation and avoiding premature wear is compliance with the instructions for maintenance, care and tuning of
the engine and suspension provided in the owner's manual. 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 dirty 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
service schedule is reached.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Fuel, oils, etc.
Use the fuels and operating fluids as specified in the Owner's Manual.
IMPORTANT INFORMATION 9
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
Some spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
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. Example: valve spring mounter (59029019000)
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 instructions 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.
Ensure that the vehicle is roadworthy after completing repair and maintenance work.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
IMPORTANT INFORMATION 10
401448-01
– Switch off the engine and remove the ignition key.
– Use straps or other suitable devices to secure the motorcycle against accidents or
falling over.
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.
11
IMPORTANT INFORMATION 12
2.1Overview of warning labels
101623-10
IMPORTANT INFORMATION 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
101615-10
Type label, Canada
IMPORTANT INFORMATION 14
101616-01
Type label, USA
101617-01
Information, emission control
IMPORTANT INFORMATION 15
101618-01
Information, noise emission
101619-01
Information, suspension setting
IMPORTANT INFORMATION 16
100338-01
Information, chain tension
101620-01
Information, fuel evaporation system
IMPORTANT INFORMATION 17
700210-01
Information, putting into operation
Notes/warnings
Pay close attention to the notes/warnings.
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 potential hazards and may therefore be injured.
IMPORTANT INFORMATION 18
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 may lead to minor injuries 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.
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.
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KTM 690 Enduro R 2012 Owner's manual

Category
Motorcycles
Type
Owner's manual
This manual is also suitable for

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