KTM 690 Enduro 2012 Owner's manual
OWNER'S MANUAL 2012
690 Enduro R EU
690 Enduro R AUS/UK
Art. no. 3211787en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
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. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 17)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development 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
© 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: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
VIEW OF VEHICLE................................................................ 12
View of vehicle, front left (example).................................... 12
View of vehicle, rear right (example)................................... 14
SERIAL NUMBERS............................................................... 16
Chassis number................................................................ 16
Type label........................................................................ 16
Engine number................................................................. 17
Key number ..................................................................... 17
Fork part number.............................................................. 18
Shock absorber part number.............................................. 18
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever .............................................................. 19
Throttle grip..................................................................... 20
Light switch..................................................................... 20
Turn signal switch ............................................................ 21
Horn button ..................................................................... 21
Emergency OFF switch...................................................... 22
Electric starter button ....................................................... 22
Ignition/steering lock ........................................................ 23
Combination instrument.................................................... 23
Combination instrument - function buttons......................... 24
Combination instrument - indicator lamps........................... 24
Combination instrument - display....................................... 25
Combination instrument - speedometer............................... 26
Setting kilometers or miles ................................................ 26
Combination instrument - time .......................................... 27
Setting the clock .............................................................. 27
Combination instrument - display ODO ............................... 28
Combination instrument - setting/resetting TRIP 1............... 28
Combination instrument - setting/resetting TRIP 2............... 29
Combination instrument - TRIP F display............................ 30
Combination instrument - coolant temperature indicator ...... 30
Opening the filler cap ....................................................... 31
Closing filler cap .............................................................. 32
Seat release..................................................................... 32
Handrails......................................................................... 33
Passenger footrests........................................................... 33
Shift lever........................................................................ 34
Foot brake lever................................................................ 35
Side stand ....................................................................... 35
PREPARING FOR USE .......................................................... 36
Advice on first use............................................................ 36
Running in the engine....................................................... 37
Loading the vehicle .......................................................... 38
RIDING INSTRUCTIONS....................................................... 40
Performing checks and vehicle care when preparing for
use ................................................................................. 40
Starting ........................................................................... 41
Starting off ...................................................................... 42
Shifting, riding................................................................. 42
Braking ........................................................................... 46
Stopping, parking............................................................. 47
Refueling......................................................................... 48
SERVICE SCHEDULE............................................................ 51
Service schedule .............................................................. 51
TABLE OF CONTENTS 4
TUNING THE CHASSIS......................................................... 54
Fork/shock absorber.......................................................... 54
Adjusting the compression damping of the fork ................... 54
Adjusting the rebound damping of the fork.......................... 55
Compression damping of the shock absorber ....................... 56
Adjusting the low-speed compression damping of the shock
absorber .......................................................................... 56
Adjusting the high-speed compression damping of the
shock absorber................................................................. 57
Adjusting the rebound damping of the shock absorber.......... 58
Measuring the unloaded rear wheel sag............................... 59
Checking the static sag of the shock absorber ..................... 60
Checking the riding sag of the shock absorber..................... 61
Adjusting the spring preload of the shock absorber x ......... 61
Adjusting the riding sag x ............................................... 63
Handlebar position ........................................................... 64
Adjusting handlebar position x ........................................ 64
SERVICE WORK ON THE CHASSIS........................................ 66
Raising the motorcycle with the lift stand ........................... 66
Removing the motorcycle from the lift stand ....................... 66
Bleeding the fork legs ....................................................... 67
Cleaning the dust boots of the fork legs .............................. 67
Loosening the fork protection............................................. 68
Positioning the fork protection ........................................... 69
Checking the steering head bearing play ............................. 69
Adjusting the play of the steering head bearing x .............. 70
Removing the seat ............................................................ 72
Mounting the seat ............................................................ 72
Removing the air filter x ................................................. 73
Installing the air filter x.................................................. 74
Checking the chain for dirt ................................................ 75
Cleaning the chain............................................................ 75
Checking the chain tension ............................................... 76
Adjusting the chain tension ............................................... 77
Check the chain, rear sprocket, engine sprocket and chain
guide............................................................................... 79
Adjusting chain guide x.................................................. 84
Adjusting basic position of clutch lever............................... 85
Checking/rectifying the fluid level of the hydraulic clutch ..... 85
Removing the engine guard ............................................... 86
Installing the engine guard ................................................ 87
BRAKES.............................................................................. 88
Checking the free travel of the hand brake lever .................. 88
Adjusting the free travel of the hand brake lever .................. 88
Checking the brake discs................................................... 89
Checking the front brake fluid level .................................... 90
Adding front brake fluid x............................................... 91
Checking the front brake linings......................................... 92
Changing the front brake linings x ................................... 93
Checking the free travel of foot brake lever.......................... 97
Adjusting the basic position of the foot brake lever x......... 97
Checking rear brake fluid level........................................... 98
Adding rear brake fluid x ................................................ 99
Checking the rear brake linings........................................ 101
Changing the rear brake linings x................................... 101
WHEELS, TIRES ................................................................ 105
Removing the front wheel x........................................... 105
Installing the front wheel x............................................ 106
TABLE OF CONTENTS 5
Removing rear wheel x.................................................. 108
Installing the rear wheel x............................................. 109
Checking the rear hub rubber dampers x........................ 110
Checking the tire condition.............................................. 112
Checking the tire air pressure .......................................... 113
Checking the spoke tension ............................................. 114
ELECTRICAL SYSTEM ........................................................ 116
Removing the battery x................................................. 116
Installing the battery x.................................................. 117
Recharging the battery x............................................... 118
Changing the main fuse .................................................. 121
Changing fuses of individual power consumers .................. 122
Removing the headlight mask with the headlight ............... 124
Installing the headlight mask with the headlight................ 126
Changing the headlight bulb............................................ 127
Changing the parking light bulb ....................................... 128
Changing the turn signal bulb.......................................... 130
Checking the headlight setting......................................... 131
Adjusting the headlight range .......................................... 131
COOLING SYSTEM ............................................................. 133
Cooling system............................................................... 133
Checking the antifreeze and coolant level ......................... 133
Checking the coolant level............................................... 135
Draining the coolant x .................................................. 137
Filling the cooling system x........................................... 138
TUNING THE ENGINE ........................................................ 141
Checking the play in the throttle cable.............................. 141
Adjusting the play in the throttle cable x........................ 142
Adjusting the engine characteristic................................... 142
Checking the basic position of the shift lever..................... 144
Adjusting the basic position of the shift lever x ............... 144
SERVICE WORK ON THE ENGINE ....................................... 146
Checking the engine oil level ........................................... 146
Changing the engine oil and filter, cleaning the oil
screens x..................................................................... 147
Draining the engine oil x............................................... 147
Removing the oil filter x................................................ 148
Cleaning the oil screens x............................................. 150
Installing the oil filter x................................................ 152
Filling up with engine oil x............................................ 152
Adding engine oil ........................................................... 153
CLEANING, CARE .............................................................. 155
Cleaning the motorcycle .................................................. 155
Checks and maintenance steps for winter operation ........... 157
STORAGE .......................................................................... 158
Storage.......................................................................... 158
Preparing for use after storage ......................................... 159
TROUBLESHOOTING.......................................................... 160
BLINK CODE ..................................................................... 163
TECHNICAL DATA - ENGINE............................................... 167
Capacity - engine oil ....................................................... 168
Capacity - coolant........................................................... 168
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 169
TECHNICAL DATA - CHASSIS ............................................. 172
Lighting equipment ........................................................ 173
Tires ............................................................................. 174
Capacity - fuel................................................................ 174
TECHNICAL DATA - FORK................................................... 175
TABLE OF CONTENTS 6
TECHNICAL DATA - SHOCK ABSORBER .............................. 176
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 178
SUBSTANCES.................................................................... 182
AUXILIARY SUBSTANCES................................................... 186
STANDARDS...................................................................... 188
INDEX ............................................................................... 189
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 optimally 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
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
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 parentheses. 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.
401448-01
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.
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 11
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 motorcycle.
– 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.
VIEW OF VEHICLE 12
3.1View of vehicle, front left (example)
601762-10
VIEW OF VEHICLE 13
1 Hand brake lever ( p. 19)
2 Clutch lever ( p. 19)
3 Handrails ( p. 33)
4 Filler cap
5 Engine number ( p. 17)
6 Shift lever ( p. 34)
7 Side stand ( p. 35)
8 Seat release ( p. 32)
8 Compression damping of the shock absorber ( p. 56)
VIEW OF VEHICLE 14
3.2View of vehicle, rear right (example)
601763-10
VIEW OF VEHICLE 15
1 Light switch ( p. 20)
1 Turn signal switch ( p. 21)
1 Horn button ( p. 21)
2 Ignition/steering lock ( p. 23)
3 Combination instrument ( p. 23)
4 Emergency OFF switch ( p. 22)
4 Electric starter button ( p. 22)
5 Throttle grip ( p. 20)
6 Shock absorber, rebound adjustment
7 Foot brake lever ( p. 35)
8 Level viewer, engine oil
9 Type label ( p. 16)
10 Chassis number ( p. 16)
SERIAL NUMBERS 16
4.1Chassis number
The chassis number 1 is stamped on the steering head on the right.
601764-10
4.2Type label
The type label 1 is located on the right side of the frame.
601765-10
SERIAL NUMBERS 17
4.3Engine number
The engine number 1 is stamped on the left side of the engine under the engine sprocket.
100211-10
4.4Key number
The key number 1 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
100179-10
SERIAL NUMBERS 18
4.5Fork part number
The fork part number 1 is stamped on the inner side of the fork stub.
601780-10
4.6Shock absorber part number
The shock absorber part number 1 is on the left of the shock absorber.
101048-10
CONTROLS 19
5.1Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
601766-10
5.2Hand brake lever
The hand break lever 1 is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.
601767-10
CONTROLS 20
5.3Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
601767-11
5.4Light switch
The light switch 1 is fitted on the left side of the handlebar.
Possible states
Low beam on – Light switch is turned downwards. In this position, the low
beam and tail light are switched on.
High beam on – Light switch is turned upwards. In this position, the high
beam and the tail light are switched on.
601768-10
CONTROLS 21
5.5Turn signal switch
The turn signal switch 1 is fitted on the left side of the handlebar.
Possible states
Turn signal off
Turn signal light, left, on – Turn signal switch pressed to the left. The turn
signal switch returns automatically to the central position after use.
Turn signal light, right, on – Turn signal switch pressed to the right. The
turn signal switch returns automatically to the central position after use.
5.6Horn button
601768-11
601768-12
To switch off the turn signal light, press the turn signal switch towards the switch case.
The horn button 1 is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
CONTROLS 22
5.7Emergency OFF switch
The emergency OFF switch 1 is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.
Emergency OFF switch on – This position is necessary for operation as the
ignition circuit is closed.
601769-10
5.8Electric starter button
The electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
601769-11
CONTROLS 23
5.9Ignition/steering lock
The ignition/steering lock 1 is located in front of the seat.
Possible states
Ignition OFF – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The ignition key can
be removed.
Ignition ON – In this position, the ignition circuit is closed and the engine
can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
600825-01
5.10Combination instrument
The combination instrument is installed in front of the handlebar.
The combination instrument is divided into 4 function areas.
1 Function buttons
2 Tachometer
3 Indicator lights
4 Display
steering locked. The ignition key can be removed.
400832-10
CONTROLS 24
5.11Combination instrument - function buttons
You can change the display mode with the MODE button 1.
Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas-
ter 2 (TRIP 2).
Press the SET button 2 to reset the trip master 1 function (TRIP 1) and trip master 2 func-
tion (TRIP 2) to 0.0.
Button 3 has no function.
400833-10
5.12Combination instrument - indicator lamps
The indicator lamps offer additional information about the operating state of the motorcycle.
Possible states
The turn signal indicator light flashes green simultaneously with the turn
signals – Turn signal light is switched on.
The idling speed indicator lamp lights up green – The transmission is
switched to idle.
401440-01
High beam indicator lamp lights up blue – High beam is switched on.
Temperature warning lamp lights up red – Coolant temperature has reached
a critical value.
Low fuel warning lamp lights up orange – Fuel level has reached the
reserve mark. Display switched to TRIP F.
CONTROLS 25
The oil pressure warning lamp lights up red – The oil pressure is too low.
FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagno-
sis) has identified an emissions- or safety-critical fault.
The battery warning lamp lights up red – The voltage in the vehicle system
is too low.
5.13Combination instrument - display
When you switch on the ignition, all display segments light up for one second as a function
test.
400836-01
LEnGth
Following the display function test, the wheel circumference LEnGth is shown for one second.
400837-01
Info
2205 mm equals the circumference of the 21" front wheel with a series production
tire.
The display then changes to the last selected mode.
CONTROLS 26
5.14Combination instrument - speedometer
The speed 1 is shown in kilometers per hour km/h or in miles per hour mph.
400838-10
5.15Setting kilometers or miles
Info
If you change the unit, the value is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is stationary.
CONTROLS 27
– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button pressed until the display mode changes from km/h to mph or
from mph to km/h.
Guideline
Activation duration of MODE button 10 s
400839-01
5.16Combination instrument - time
The time is shown in area 1 of the display.
Info
After reconnecting the battery or changing the fuse, the time must be reset.
400838-11
5.17Setting the clock
Condition
The motorcycle is stationary.
CONTROLS 28
– Switch on the ignition by turning the ignition key to position ON .
– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button and the SET button pressed simultaneously.
The time display begins to flash.
– Press the MODE button to set the hour.
– Press the SET button to set the minute.
– Keep the MODE button and the SET button pressed simultaneously.
400838-01
5.18Combination instrument - display ODO
In the ODO display mode, the total distance traveled is shown in kilometers or miles.
400839-01
The time is set.
Info
This value is retained, even if the battery is disconnected and/or the fuse blows.
5.19Combination instrument - setting/resetting TRIP 1
Info
The TRIP 1 trip counter runs constantly and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.
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