KTM 690 Enduro R US 2011 Owner's manual

Category
Motorcycles
Type
Owner's manual

This manual is also suitable for

OWNER'S MANUAL 2011
690 Enduro R USA
Art. no. 3211654en
DEAR KTM CUSTOMER 1
DEAR KTMCUSTOMER
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 a lot of enjoyment in riding this 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 vehicles 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
© 2010 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................................................................ 20
View of vehicle, front left................................................... 20
View of vehicle, rear right.................................................. 22
SERIAL NUMBERS............................................................... 24
Chassis number................................................................ 24
Type label........................................................................ 24
Engine number................................................................. 25
Key number ..................................................................... 25
Fork part number.............................................................. 26
Shock absorber part number.............................................. 26
CONTROLS.......................................................................... 27
Clutch lever ..................................................................... 27
Hand brake lever .............................................................. 27
Throttle grip..................................................................... 28
Light switch ..................................................................... 28
Turn signal switch ............................................................ 29
Horn button ..................................................................... 29
Emergency OFF switch...................................................... 30
Electric starter button ....................................................... 30
Ignition/steering lock ........................................................ 31
Combination instrument.................................................... 31
Combination instrument - function buttons ......................... 32
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 the filler cap ....................................................... 39
Closing filler cap .............................................................. 40
Seat release ..................................................................... 40
Handrails......................................................................... 41
Passenger footrests........................................................... 41
Shift lever........................................................................ 42
Foot brake lever................................................................ 43
Side stand ....................................................................... 43
PUTTING INTO OPERATION.................................................. 44
Advice on first use............................................................ 44
Running in the engine....................................................... 45
Loading the vehicle .......................................................... 46
RIDING INSTRUCTIONS ....................................................... 48
Performing checks and vehicle care when preparing for
use ................................................................................. 48
Starting ........................................................................... 49
Starting off ...................................................................... 50
Shifting, riding................................................................. 50
Braking ........................................................................... 54
Stopping, parking ............................................................. 55
Refueling......................................................................... 56
TABLE OF CONTENTS 4
SERVICE SCHEDULE............................................................ 59
Service schedule .............................................................. 59
TUNING THE CHASSIS......................................................... 62
Fork/shock absorber.......................................................... 62
Adjusting the compression damping of the fork ................... 62
Adjusting the rebound damping of the fork.......................... 63
Compression damping of the shock absorber ....................... 64
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 64
Adjusting the high-speed compression damping of the
shock absorber ................................................................. 65
Adjusting the rebound damping of the shock absorber.......... 66
Measuring the unloaded rear wheel sag............................... 67
Checking the static sag of the shock absorber ..................... 68
Checking the riding sag of the shock absorber ..................... 69
Adjusting the spring preload of the shock absorber x ......... 69
Handlebar position ........................................................... 71
Adjusting handlebar position x ........................................ 71
SERVICE WORK ON THE CHASSIS........................................ 73
Raising the motorcycle with the lift stand ........................... 73
Removing the motorcycle from the lift stand ....................... 73
Bleeding the fork legs ....................................................... 74
Cleaning the dust boots of the fork legs .............................. 74
Loosening the fork protection............................................. 75
Positioning the fork protection ........................................... 76
Checking the steering head bearing play ............................. 76
Adjusting the play of the steering head bearing x .............. 77
Removing the seat............................................................ 78
Mounting the seat ............................................................ 79
Removing the air filter x ................................................. 79
Installing the air filter x.................................................. 80
Checking the chain for dirt ................................................ 81
Cleaning the chain............................................................ 81
Checking the chain tension ............................................... 83
Adjusting the chain tension ............................................... 84
Check the chain, rear sprocket, engine sprocket and chain
guide............................................................................... 86
Adjusting chain guide x .................................................. 91
Adjusting basic position of clutch lever............................... 92
Checking/rectifying the fluid level of the hydraulic clutch ..... 92
Removing the engine guard ............................................... 93
Installing the engine guard ................................................ 94
BRAKES.............................................................................. 95
Checking the free travel of the hand brake lever .................. 95
Adjusting the free travel of the hand brake lever .................. 95
Checking the brake discs................................................... 96
Checking the front brake fluid level .................................... 97
Adding front brake fluid x............................................... 98
Checking the front brake linings......................................... 99
Changing the front brake linings x ................................. 100
Checking the free travel of foot brake lever........................ 104
Adjusting the basic position of the foot brake lever x....... 104
Checking rear brake fluid level......................................... 105
Adding rear brake fluid x .............................................. 106
Checking the rear brake linings........................................ 108
Changing the rear brake linings x................................... 108
WHEELS, TIRES ................................................................ 112
Removing the front wheel x........................................... 112
TABLE OF CONTENTS 5
Installing the front wheel x............................................ 113
Removing rear wheel x.................................................. 115
Installing the rear wheel x............................................. 116
Checking the rear hub rubber dampers x ........................ 117
Checking the tire condition.............................................. 118
Checking the tire air pressure .......................................... 120
Checking the spoke tension ............................................. 121
ELECTRICAL SYSTEM ........................................................ 123
Removing the battery x................................................. 123
Installing the battery x.................................................. 124
Recharging the battery x............................................... 124
Changing the main fuse .................................................. 126
Changing fuses of individual power consumers .................. 128
Removing the headlight mask with the headlight ............... 130
Installing the headlight mask with the headlight................ 132
Changing the headlight bulb............................................ 133
Changing the parking light bulb ....................................... 134
Changing the turn signal bulb.......................................... 135
Changing the tail light..................................................... 136
Checking the headlight setting......................................... 137
Adjusting the headlight range .......................................... 137
COOLING SYSTEM ............................................................. 139
Cooling system ............................................................... 139
Checking the antifreeze and coolant level ......................... 139
Checking the coolant level............................................... 141
Draining the coolant x .................................................. 143
Filling the cooling system x........................................... 144
TUNING THE ENGINE ........................................................ 146
Checking the play in the throttle cable.............................. 146
Adjusting the play in the throttle cable x ........................ 147
Adjusting the engine characteristic................................... 147
SERVICE WORK ON THE ENGINE ....................................... 149
Checking the engine oil level ........................................... 149
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 150
Draining the engine oil x............................................... 150
Removing the oil filter x................................................ 151
Cleaning the oil screens x............................................. 153
Installing the oil filter x ................................................ 155
Filling up with engine oil x............................................ 155
Adding engine oil ........................................................... 156
CLEANING, CARE .............................................................. 158
Cleaning the motorcycle.................................................. 158
Protective treatment for winter operation .......................... 160
STORAGE .......................................................................... 161
Storage.......................................................................... 161
Preparing for use after storage ......................................... 162
TROUBLESHOOTING.......................................................... 163
BLINK CODE ..................................................................... 166
TECHNICAL DATA - ENGINE............................................... 171
Capacity - engine oil ....................................................... 172
Capacity - coolant........................................................... 172
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 173
TECHNICAL DATA - CHASSIS ............................................. 176
Lighting equipment ........................................................ 177
Tires ............................................................................. 178
Capacity - fuel................................................................ 178
TECHNICAL DATA - FORK................................................... 179
TABLE OF CONTENTS 6
TECHNICAL DATA - SHOCK ABSORBER .............................. 180
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 182
SUBSTANCES.................................................................... 185
AUXILIARY SUBSTANCES................................................... 189
STANDARDS...................................................................... 191
INDEX ............................................................................... 192
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 in 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 following typographical formats are used.
Specific name Identifies a proprietary name.
Name
®
Identifies a protected name.
Brandâ„¢ Identifies a brand in merchandise traffic.
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 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.
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 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 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
– 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.
IMPORTANT INFORMATION 11
IMPORTANT INFORMATION 12
2.1Overview of warning labels
800103-10
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
800110-01
Type label, Canada
IMPORTANT INFORMATION 14
B00112-01
Type label, USA
101072-01
Information, emission control
IMPORTANT INFORMATION 15
101074-01
Information, noise emission
B00111-01
Information, suspension setting
IMPORTANT INFORMATION 16
100338-01
Information, chain tension
101073-01
Information, fuel evaporation system
700210-01
Information, putting into operation
IMPORTANT INFORMATION 17
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.
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.
IMPORTANT INFORMATION 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: (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
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KTM 690 Enduro R US 2011 Owner's manual

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

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