KTM 690 ENDURO EU, 690 ENDURO UK, 690 ENDURO AUS User Manual

OWNER'S MANUAL 2009

690 ENDURO EU

690 ENDURO AUS/UK

ART. NO. 3211357en

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 great pleasure riding the 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 motorcycles 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

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, 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

CONTENTS 3

CONTENTS

MEANS OF REPRESENTATION ............................................... 6

IMPORTANT NOTES............................................................... 7

VIEW OF VEHICLE................................................................ 12

View of vehicle, front left side............................................ 12

View of vehicle, rear right .................................................. 14

LOCATION OF SERIAL NUMBERS ......................................... 16

Chassis number................................................................ 16

Type label........................................................................ 16

Key number ..................................................................... 17

Engine number................................................................. 17

Fork part number.............................................................. 18

Shock absorber part number .............................................. 18

CONTROLS.......................................................................... 19

Clutch lever ..................................................................... 19

Hand brake lever .............................................................. 19

Light switch ..................................................................... 20

Flasher switch.................................................................. 20

Horn button ..................................................................... 21

Emergency OFF switch...................................................... 21

Electric starter button ....................................................... 22

Ignition/steering lock ........................................................ 22

Combination instrument.................................................... 23

Combination instrument - function buttons ......................... 23

Combination instrument - tachometer................................. 24

Combination instrument - control 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 filler cap............................................................. 31

Closing filler cap .............................................................. 31

Handrails......................................................................... 32

Seat release ..................................................................... 32

Passenger footrests........................................................... 33

Shift lever........................................................................ 33

Foot brake pedal .............................................................. 34

Side stand ....................................................................... 35

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION......................................................................... 36

Advice on first use ............................................................ 36

Running in the engine....................................................... 37

Loading the vehicle .......................................................... 38

RIDING INSTRUCTIONS ....................................................... 40

Checks before putting into operation .................................. 40

Starting ........................................................................... 41

Starting up ...................................................................... 43

Shifting, riding................................................................. 43

Braking ........................................................................... 46

Stopping, parking ............................................................. 47

Refueling......................................................................... 49

CONTENTS 4

SERVICE SCHEDULE............................................................ 51

Important maintenance work to be carried out by an

authorized KTM workshop. ................................................ 51

Important maintenance work to be carried out by an

authorized KTM workshop. (as additional order)................... 53

MAINTENANCE WORK ON CHASSIS AND ENGINE ................. 55

Jacking up the motorcycle ................................................. 55

Removing the motorcycle from the work stand..................... 55

Fork/shock absorber.......................................................... 56

Adjusting the compression damping of the fork ................... 56

Adjusting the rebound damping of the fork.......................... 57

Compression damping of the shock absorber ....................... 58

Adjusting the low-speed compression damping of the shock

absorber .......................................................................... 58

Adjusting the high-speed compression damping of the

shock absorber ................................................................. 60

Adjusting the rebound damping of the shock absorber.......... 61

Bleeding fork legs............................................................. 62

Cleaning the dust boots of the fork legs .............................. 63

Loosening the fork protection............................................. 64

Positioning the fork protection ........................................... 64

Checking play of steering head bearing x.......................... 65

Adjusting play of steering head bearing x.......................... 66

Handlebar position ........................................................... 67

Adjusting handlebar position x ........................................ 67

Checking chain dirt .......................................................... 68

Cleaning the chain............................................................ 68

Checking the chain tension ............................................... 69

Adjusting the chain tension ............................................... 70

Checking rear sprocket / engine sprocket for wear ................ 72

Checking chain wear......................................................... 73

Adjusting chain guide x .................................................. 74

Checking brake discs ........................................................ 74

Checking free play of hand brake lever................................ 75

Adjusting free travel of handbrake lever .............................. 76

Checking the front brake fluid level .................................... 77

Adding front brake fluid x ............................................... 77

Checking the front brake linings......................................... 79

Changing the front brake linings x ................................... 80

Checking free play of foot brake lever ................................. 83

Adjusting basic position of foot brake pedal x ................... 84

Checking rear brake fluid level ........................................... 85

Adding rear brake fluid x ................................................ 85

Checking the rear brake linings .......................................... 87

Changing the rear brake linings x..................................... 87

Removing the front wheel x............................................. 90

Installing the front wheel x.............................................. 92

Removing rear wheel x.................................................... 93

Installing the rear wheel x............................................... 94

Checking the rear hub rubber dampers x .......................... 95

Checking the tire condition................................................ 96

Checking tire air pressure .................................................. 98

Checking spoke tension..................................................... 99

Removing the seat .......................................................... 100

Mounting the seat .......................................................... 101

Removing the battery x................................................. 101

Installing the battery x.................................................. 102

CONTENTS 5

Recharging the battery x............................................... 103

Changing the main fuse .................................................. 105

Changing the fuses of power consumers............................ 107

Adjusting the engine characteristic................................... 109

Removing the headlight mask with the headlight ............... 111

Refitting the headlight mask with the headlight................. 112

Changing the headlight bulb............................................ 113

Changing the parking light bulb ....................................... 114

Changing the flasher bulb ............................................... 115

Checking headlamp setting.............................................. 116

Adjusting the headlight range .......................................... 117

Removing the air filter x ............................................... 117

Installing the air filter x ................................................ 118

Cooling system ............................................................... 119

Checking the antifreeze and coolant level ......................... 120

Checking the coolant level............................................... 122

Draining the coolant x .................................................. 124

Filling the cooling system x........................................... 125

Adjusting basic position of clutch lever............................. 127

Checking/rectifying the fluid level of the hydraulic clutch ... 127

Checking play in gas Bowden cable.................................. 128

Adjusting the play in the gas Bowden cable x.................. 129

Removing the engine guard ............................................. 130

Installing the engine guard .............................................. 130

Checking engine oil level................................................. 131

Changing the engine oil and filter, cleaning the oil

screens x..................................................................... 131

Draining the engine oil x............................................... 132

Removing the oil filter x................................................ 133

Installing the oil filter x ................................................ 135

Cleaning the oil screens x ............................................. 135

Filling up with engine oil x............................................ 137

Topping up engine oil ..................................................... 138

TROUBLESHOOTING.......................................................... 140

FLASHING CODE ............................................................... 143

CLEANING......................................................................... 148

Cleaning motorcycle ....................................................... 148

CONSERVING FOR WINTER OPERATION ............................. 150

Conservation for winter operation ..................................... 150

STORAGE .......................................................................... 151

Storage.......................................................................... 151

Putting into operation after storage .................................. 152

TECHNICAL DATA - ENGINE ............................................... 153

Capacity- engine oil ........................................................ 154

Capacity - coolant........................................................... 154

TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........... 155

TECHNICAL DATA - CHASSIS ............................................. 158

Lighting equipment ........................................................ 159

Capacity - fuel................................................................ 160

TECHNICAL DATA - FORK................................................... 161

TECHNICAL DATA - SHOCK ABSORBER .............................. 162

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 164

SUBSTANCES.................................................................... 167

AUXILIARY SUBSTANCES................................................... 171

STANDARDS...................................................................... 173

INDEX ............................................................................... 174

MEANS OF REPRESENTATION 6

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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally
by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained in the following.

Specific name Identifies a proprietary name.

®

Name

Brand™ Identifies a trademark.

Identifies a protected name.

IMPORTANT NOTES 7

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.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. 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 ser­vice schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance 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; oth­erwise 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 NOTES 8

Spare parts, accessories

In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in
an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.

The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com

Work rules

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 advice 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.
Following repairs or servicing, the vehicle must be checked for roadworthiness.

Transport

Note

Danger of damage The parked vehicle can roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components get very hot when the machine is driven.

– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm

from being run. Always let the vehicle cool first.

– Switch off the engine and remove the ignition key.
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT NOTES 9

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/warning.

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 dangers and may therefore be injured.

IMPORTANT NOTES 10

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 will possibly lead to light injury 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.

11

VIEW OF VEHICLE 12

3.1View of vehicle, front left side

800070-10

VIEW OF VEHICLE 13

1 Hand brake lever
2 Clutch lever
3 Handrail
4 Filler cap
5 Seat
6 Front brake caliper
7 Shift lever
8 Engine number
9 Side stand
10 Footrest
11 Seat release strap

VIEW OF VEHICLE 14

3.2View of vehicle, rear right

800071-10

VIEW OF VEHICLE 15

1 Ignition/steering lock
2 Rear mirror
3 Light switch, flasher switch, horn button
4 Combination instrument
5 Emergency OFF switch, electric starter button
6 Throttle grip
7 Chassis number
8 Brake caliper, rear
9 Passenger footrest
10 Shock absorber, rebound damping
11 Foot brake pedal
12 Level viewer, engine oil

LOCATION OF SERIAL NUMBERS 16

4.1Chassis number

The chassis number  is stamped on the steering head on the right.

100217-10

4.2Type label

Type label  is located on the upper right frame tube below the seat.

100218-10

LOCATION OF SERIAL NUMBERS 17

4.3Key number

The key number  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

4.4Engine number

The engine number  is stamped on the left side of the engine under the engine sprocket.

100211-10

LOCATION OF SERIAL NUMBERS 18

4.5Fork part number

The fork part number  is stamped on the inner side of the fork stub.

800072-10

4.6Shock absorber part number

The shock absorber part number  is on the right of the shock absorber.

100216-10

CONTROLS 19

5.1Clutch lever

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

100219-10

5.2Hand brake lever

The hand break lever  is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.

100220-10

CONTROLS 20

5.3Light switch

The light switch  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.

100222-10

5.4Flasher switch

The flasher switch  is fitted on the left side of the handlebar.

Possible states

Flasher light off
Flasher light, left, on – Flasher switch pressed to the right. The flasher

switch returns automatically to the central position after use.

Flasher light, right, on – Flasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.

100223-10

To switch off the flasher light, press the flasher switch towards the switch case.

CONTROLS 21

5.5Horn button

The horn button  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.

100224-10

5.6Emergency OFF switch

The emergency OFF switch  is fitted on the left 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.

100225-10

CONTROLS 22

5.7Electric starter button

The electric starter button  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.

100226-10

5.8Ignition/steering lock

The ignition/steering lock  is in front of the upper triple clamp.

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 broken and the

600825-01

steering locked. The ignition key can be removed.

CONTROLS 23

5.9Combination instrument

The combination instrument is installed in front of the handlebar.
The combination instrument is divided into 4 function areas.

 Function buttons
 Tachometer
 Indicator lights
 Display

700116-01

5.10Combination instrument - function buttons

You can change the display mode with the MODE button .
Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas­ter 2 (TRIP 2).
Press the SET button  to reset the trip master 1 function (TRIP 1) and trip master 2 func­tion (TRIP 2) to 0.0.
Button  has no function.

700117-01

CONTROLS 24

5.11Combination instrument - tachometer

The tachometer  shows the engine speed in revolutions per minute.
The red marking  shows the excess speed range of the engine.

100118-10

5.12Combination instrument - control lamps

The control lamps offer additional information about the operating state of the motorcycle.

Possible states

The flasher control lamp flashes green simultaneously with the flashers
– Flasher light is switched on.

The idle speed indicator lamp lights up green – The transmission is
switched to idle.

High beam indicator lamp lights up blue – High beam is switched on.

100119-10

Temperature warning lamp shows red – Coolant has reached a critical
value.

Fuel level warning lamp shows orange – Fuel level has reached the reserve
mark. Display switched to TRIP F.

CONTROLS 25

FI warning lamp (MIL) lights/flashes orange – The OBD has detected an

emission- or safety-critical fault.

Battery warning lamp shows red – Voltage in vehicle system too low.

5.13Combination instrument - Display

When you switch on the ignition, all display segments light up for a second as a function
test.

700118-01

LEnGTth

Following the display function test, the wheel circumference LEnGth is shown for one sec­ond.

Info

2205 mm equals the circumference of the 21" front wheel with a series production
tire.

400404-01

The display then changes to the last selected mode.

CONTROLS 26

5.14Combination instrument - speedometer

The speed  is shown in kilometers per hour km/h or in miles per hour Mph.

700114-01

5.15Setting kilometers or miles

Info

If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.

Condition

The motorcycle is standing.

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

700120-01

5.16Combination instrument - time

The time is shown in area  of the display.

Info

The time has to be reset after the battery is reconnected or when the fuse is
changed.

700115-01

5.17Setting the clock

Condition

The motorcycle is standing.

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.

700115-10

5.18Combination instrument - display ODO

In the ODO display mode, the total distance traveled is shown in kilometers or miles.

700120-01

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 is always running 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.