Instruction/ maintenance manual of the product 690 ENDURO EU, 690 ENDURO AUS/UK KTM
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OWNER 'S MANU AL 2008 690 ENDUR O EU 690 ENDURO AUS/UK ART. NO. 3211239e n.
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DEAR KTM CUS TOMER 1 DEAR KTM CUSTOMER Congratulations on yo ur decision to purchase a KT M motorcycle. You are no w the owner of a state-of-the- art sports motorcycle tha t will give you enormous ple asure if you service and mai ntain it accordingly.
DEAR KTM CUS TOMER 2 © 2008 by KTM-Sportm otorcycle AG, Mattighof en Austria All rights reserved Reproduction, even in p art, is permitted only with the e xpress written permiss ion of the copyright owner.
CONTENTS 3 CONTENTS MEANS OF REPRESEN TATION ............................ ................... 7 IMPORTANT NOTES ............................ ............................... .... 8 VIEW OF VEHICLE ............................ ..........................
CONTENTS 4 Stopping, parking ................................ ............................. 49 Refueling ...................... ............................... .................... 51 GREASING AND SERVI CE TABLE .... ............................... ..
CONTENTS 5 Removing the seat ............................................... ........... 102 Mounting the seat .... ............................... ....................... 103 Removing the battery x .............................. .................
CONTENTS 6 STANDARDS ................................ ............................... ....... 171 INDEX .................... ..........................
MEANS OF RE PRESENTA TION 7 1 MEANS OF REPRESENTAT ION Symbols used The symbols used are ex plained in the following. Indicates an expecte d reaction (e.g. of a work step or a fu nction). Indicates an unexpec ted reaction (e.g. of a work ste p or a function).
IMPORTA NT NOTES 8 2 IMPORTANT NOTES Use definition KTM sport motorcycle s are designed and constr ucted to meet the normal de mands of regular road and lig ht offroad operation (dirt ro ads), but not for use on race cours es. Info The motorcycle is auth orized for public road traffic i n the homologous versio n only.
IMPORTA NT NOTES 9 Spare parts, access ories For your own safety, use on ly spare parts and access ories approved by KTM, an d have these mounted onl y in an authorized KTM work shop. KTM accepts no liabilit y for other products and any re sulting damage or loss.
IMPORTA NT NOTES 10 Notes/warning note s Pay attention to the spec ified notes and warnings. Info Various notes and warn ing labels are attached to the v ehicle. Do not remove any n otes or warning labels. If the y are missing, you or others may not recogni ze dangers and may theref ore be injured.
IMPORTA NT NOTES 11 – The owner's manual is an i mportant component of th e motorcycle and shoul d be handed over to the new own er if the vehicle is sold.
VIEW OF VEHICL E 12 3 VIEW OF VEHICLE 3.1 View of vehicle, fron t left side 100234-10.
VIEW OF VEHICL E 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 VEHICL E 14 3.2 View of vehicle, rear r ight side 100235-10.
VIEW OF VEHICL E 15 1 Ignition/steering loc k 2 Rear mirror 3 Light switch, flasher s witch, horn 4 Combination instrum ent 5 Emergency OFF switc h, electric starter button 6 Throttle grip 7 Chassis n.
LOCATION O F SERIAL NUM BERS 16 4 LOCATION OF SERIAL NU MBERS 4.1 Chassis number 100217-10 The chassis number i s stamped on the steering h ead on the right. 4.2 Type label 100218-10 Type label is located on t he upper right frame tube be low the seat.
LOCATION O F SERIAL NUM BERS 17 4.3 Key number 100179-10 The key number can be f ound on the KEYCODECAR D . Info You need the key numbe r to order a spare key. Keep the KEYCODECARD in a safe place. 4.4 Engine number 100211-10 The engine number is s tamped on the left side of the en gine under the engine spr ocket.
LOCATION O F SERIAL NUM BERS 18 4.5 Fork part number 100214-10 The fork part number is s tamped on the inner side of th e fork stub. 4.6 Shock absorber par t number 100216-10 Shock absorber part n umber can be viewed fro m the right side.
OPERATIN G ELEMENTS 19 5 OPERATING ELEMENTS 5.1 Clutch lever 100219-10 The clutch lever is fitte d on the left side of the handleba r. The clutch is hydraulic ally operated and self-ad justing. 5.2 Hand brake lever 100220-10 The hand break lever is f itted on the right side of the hand lebar.
OPERATIN G ELEMENTS 20 5.3 Light switch 500020-01 The light switch is fitted o n the left side of the handleba r. Possible states Low beam on – Light switch i s turned downwards. In this p osition, the low beam and tail light are swit ched on.
OPERATIN G ELEMENTS 21 5.5 Headlight flasher sw itch 500020-11 The headlight flashe r switch is fitted on the left si de of the handlebar. Possible states • Headlight flasher sw itch in neutral position • Headlight flasher sw itch pressed – In this pos ition, the headlight flash er (high beam) is actuated.
OPERATIN G ELEMENTS 22 5.7 Flasher switch 100223-10 The flasher switch is fit ted on the left side of the handle bar. Possible states Flasher light off Flasher light, left, on – Flasher switch presse d to the right. The flasher switch returns automa tically to the central positi on after use.
OPERATIN G ELEMENTS 23 5.9 Horn 100224-10 The horn button is fitte d on the left side of the handleba r. Possible states • Horn button in neutra l position • Horn button presse d – The horn is operated in this p osition.
OPERATIN G ELEMENTS 24 5.11 Electric starter button 100226-10 The electric starter butt on is fitted on the right side of th e handlebar. Possible states • Electric starter button in basic position • Electric starter button pressed – In this positi on, the electric starter is act uated.
OPERATIN G ELEMENTS 25 5.13 Combination instru ment 700116-01 The combination inst rument is attached in fromt o f the handlebar. The combination inst rument is divided into 4 func tion areas. Function buttons Tachometer Indicator lights Display 5.
OPERATIN G ELEMENTS 26 5.15 Combination instru ment - tachometer 100118-10 The tachometer dis plays the engine speed in re volutions per minute.
OPERATIN G ELEMENTS 27 Battery warning lamp lig hts up – Voltage in electr ical system too low. 5.17 Combination instru ment - Display 700118-01 When you switch on the ign ition, all display segmen ts light up for a second as a func tion test.
OPERATIN G ELEMENTS 28 5.18 Combination instru ment - speed display 700114-01 The speed is displaye d in kilometers per hour k m/h or miles per hour M ph . 5.19 Setting kilometers o r miles Info If you change the unit, the O DO value is retained and con verted accordingly.
OPERATIN G ELEMENTS 29 700120-01 – Switch on the ignition by tu rning the ignition key in the po sition . – Press the MODE but ton several times until the ODO display mode is activ e. – Keep the MODE button p ressed until the display mo de changes from Km/h t o Mph or from Mph to Km/h .
OPERATIN G ELEMENTS 30 700115-10 – Switch on the ignition by tu rning the ignition key in the po sition . – Press the MODE but ton several times until the ODO display mode is activ e. – Keep the MODE but ton and the SET button p ressed simultaneous ly.
OPERATIN G ELEMENTS 31 700121-01 – Switch on the ignition by tu rning the ignition key in the po sition . – Press the MODE but ton several times until the TRIP 1 display mode is ac tive. – Keep the SET button p ressed.
OPERATIN G ELEMENTS 32 5.25 Combination instru ment - TRIP F displa y 700123-01 When the fuel level reach es the reserve mark, the dis play automatically cha nges to TRIP F and begins to count from 0.0 , regardless of which d isplay mode was previou sly active.
OPERATIN G ELEMENTS 33 5.27 Opening filler cap 100227-10 – Lift the cover of the fille r cap and insert the igniti on key. – Turn the ignition key 90° c ounterclockwise and re move the filler cap. Info The filler cap has a tank air ve nt system.
OPERATIN G ELEMENTS 34 5.29 Handrails 100229-10 The handrails are use d for moving the motorcyc le around. When you have a passen ger, the passenger can ho ld on the handrails during th e journey. 5.30 Seat release 100230-10 The seat can be released u sing strap .
OPERATIN G ELEMENTS 35 5.31 Passenger footres ts 100231-01 The passenger footre sts can be folded up and dow n. Possible states • Passenger footrests f olded up – For operation wi thout a passenger. • Passenger footrests f olded down – For operati on with a passenger.
OPERATIN G ELEMENTS 36 100212-10 The gear positions can b e seen in the photograph. The neutral or idle positio n is between the first and seco nd gears. 5.33 Foot brake pedal 100232-10 The footbrake pedal i s located in front of the right foot rest.
OPERATIN G ELEMENTS 37 5.34 Side stand 100233-10 The side stand is coup led with the safety electric st arter system - see the riding in struc- tions. Possible states • Side stand folded out – T he vehicle can be suppor ted on the side stand.
GENERAL TI PS AND HINTS ON PUTTING INT O OPERATIO N 38 6 GENERAL TIPS AND HINTS O N PUTTING INTO OPERATION 6.1 Advice on first use Danger Danger of accident s Danger from inadequa te traffic experience. – Do not use the vehicle if you a re inexperienced or if you ha ve consumed alcohol or d rugs.
GENERAL TI PS AND HINTS ON PUTTING INT O OPERATIO N 39 Info When using your vehic le, remember that others m ay feel disturbed by exces sive noise. – Make sure that the pre-de livery inspection work ha s been carried out by an auth orized KTM workshop.
GENERAL TI PS AND HINTS ON PUTTING INT O OPERATIO N 40 6.2 Running in the engine – During the running-in ph ase, do not exceed the spec ified engine speed and en gine performance. Specification Maximum engine spee d During the first: 1,000 km (621.
GENERAL TI PS AND HINTS ON PUTTING INT O OPERATIO N 41 Warning Danger of accident s Poor visibility for other roa d users due to slipped bagg age. – If the tail light is covered, yo u are less visible to following t raffic, especially in the da rk.
RIDING INST RUCTIONS 42 7 RIDING INSTRUCTIONS 7.1 Checks before putti ng into operation Info Make sure that the motor cycle is in a perfect technica l condition before use. In the interests of riding sa fety, make a habit of making a g eneral check before you ri de.
RIDING INST RUCTIONS 43 7.2 Starting Danger Danger of poisoning Exhaust gases are pois onous and can result in unc onsciousness and/or d eath. – When running the engin e, always make sure there is s ufficient ventilation, a nd do not start or run the engine in a c losed space.
RIDING INST RUCTIONS 44 100239-10 – Turn the emergency OF F switch to the position . – Switch on the ignition by tu rning the ignition key in the po sition . After switching on the ign ition, you can hear the fuel pum p working for about 2 seconds.
RIDING INST RUCTIONS 45 7.3 Starting up – Pull the clutch lever, eng age 1st gear, release the clu tch lever slowly and simul taneously open the thrott le carefully. 7.4 Shifting, riding Warning Danger of accident s An abrupt load alteration s can cause the vehicle to ge t out of control.
RIDING INST RUCTIONS 46 Warning Danger of accident s Reduced road grip with co ld tires. – On every journey, take th e first miles carefully at mod erate speed until the tires re ach operating temperat ure and optimal road grip is ensured. Warning Danger of accident s Reduced road grip with ne w tires.
RIDING INST RUCTIONS 47 Note Engine failure Ove rheating of engine. – If the coolant temperatu re warning lamp lights up, st op and switch off the engine . Allow the engine to cool down a nd check the coolant level in the radia tor, and top up if necessary.
RIDING INST RUCTIONS 48 – For example, if the engin e stalls at a junction, just pull th e clutch and press the elect ric starter button. You do not n eed to shift into neutral. – Switch off the engine if you e xpect to be standing for a long ti me.
RIDING INST RUCTIONS 49 Warning Danger of accident s Brake system failure. – If the foot brake pedal is not re leased, the brake linings d rag permanently. The rea r brake can fail due to overhea ting. Take your foot off the foot brake pe dal if you do not want to bra ke.
RIDING INST RUCTIONS 50 Warning Danger of burns Som e vehicle component s get very hot when the machin e is driven. – Do not touch hot compon ents such as exhaust syst em, radiator, engine, sho ck absorber and brakes. A llow these component s to cool down before startin g work on them.
RIDING INST RUCTIONS 51 – Lock the steering by mov ing the handlebar to the left, p ressing down the ignition k ey in the position and tur ning it to the position . To make locking the stee ring easier, move the hand lebar a little to the left and right .
RIDING INST RUCTIONS 52 400405-10 – switch off engine. – Open the filler cap. ( P. 33) – Fill the fuel tank with fuel up to m easurement . Specification Measurement of 20 mm (0.79 in) Fuel tank content 12 l (3.2 US gal) Super unleaded (ROZ 95 / R ON 95 / PON 91) ( P.
GREASING A ND SERVICE T ABLE 53 8 GREASING AND SERVICE TA BLE 8.1 Important mainten ance work to be carried o ut by an authorized KTM w orkshop. K10N K50A K100A J1A J2A Engine Change engin e oil and oil filter, clean oil scree ns. x ( P. 133) ••••• Check and adjust valve c learance.
GREASING A ND SERVICE T ABLE 54 K10N K50A K100A J1A J2A Attachments Check the func tioning of the electrical eq uipment. • • • • • Check screws and nuts fo r tightness. • • • • • Brakes Check the front brake lini ngs. ( P. 81) • • • • • Check the rear brake linin gs.
GREASING A ND SERVICE T ABLE 55 K10N K50A K100A J1A J2A Wheels Check the chain wear. ( P. 74) • • • • • Check rear sprocket / e ngine sprocket for tigh tness. • • • • • Check rear sprocket / e ngine sprocket for wea r. ( P. 73) • • • • • Check the chain tensio n.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 56 9 MAINTENANCE WORK ON C HASSIS AND ENGINE 9.1 Jacking up the motorc ycle Note Danger of damage D anger of damage by the veh icle running away or falling o ver. – Always place the vehic le on a firm and even surface.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 57 9.3 Fork/shock absorb er 100242-01 The fork and the shock abs orber offer many options o f adapting the chassis to yo ur riding style and the payload. Info To help you adapt the vehi cle, we have summarized o ur findings in Table .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 58 – Turn back counterclo ckwise the number of click s corresponding to the fork t ype. Specification Compression damp ing Comfort 20 clicks Standard 15.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 59 – Turn back counterclo ckwise the number of click s corresponding to the fork t ype. Specification Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to incre ase damping, turn counte rclockwise to reduce su spension damping.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 60 100245-10 – Turn the adjusting scre w clockwise with a screw driver until it stops. Info Do not loosen nut ! – Turn back counterclo ckwise the number of click s corresponding to the sho ck absorber type.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 61 Info The high-speed settin g can be seen during the fast co mpression of the shock a bsorber. 100246-10 – Turn the adjusting scre w clockwise with an ope n-ended spanner until it sto ps.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 62 9.9 Adjusting rebound d amping of the shock abs orber Danger Danger of accident s The shock absorber is un der high pressure. – The shock absorber is fil led with highly compress ed nitrogen, so never dism antle the shock absorbe r or carry out any mainte- nance on it yourself.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 63 100248-10 – Remove bleeder scre ws briefly. Any excess pressure e scapes from the interior of th e fork. – Mount and tighten blee der screws. Info Carry out this action on bot h fork legs. 9.11 Cleaning dust boots o f fork legs – Jack up the motorcycle .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 64 – Remove excess oil. – Position the fork protec tion. ( P. 64) – Remove the motorcyc le from the work stand. ( P. 56) 9.12 Loosening the fork pro tection 100292-10 – Remove screws and t ake off clamp.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 65 9.14 Checking play of stee ring head bearing x Warning Danger of accident s Unsafe riding behavio r due to incorrect steering h ead bearing play. – The steering head bear ing play should be adjuste d immediately in an autho rized KTM workshop.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 66 9.15 Adjusting play of stee ring head bearing x – Jack up the motorcycle . ( P. 56) 100297-10 – Loosen screw . Rem ove screw . – Loosen and retighten s crew . Specification Screw, top steering hea d M20x1.
0 0 B B 0 0 A A MAINTENA NCE WORK O N CHASSIS AN D ENGINE 67 9.16 Adjusting the handle bar angle x 100279-10 – Loosen screw . – Move the handlebar to th e desired position and slig htly tichten the screws. – Move the handlebar ca refully in both directions as f ar as it will go.
0 0 2 2 0 0 1 1 MAINTENA NCE WORK O N CHASSIS AN D ENGINE 68 9.18 Adjusting handleb ar position x 400271-10 – Remove the four screws . Remove the handle bar clamp. Remove the ha ndlebar and lay it to one side. Info Protect the motorcycl e and its attachments from d amage by covering them .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 69 9.19 Checking chain dirt – Check the chain for coars e dirt accumulation. » If the chain is very dirty: – Clean the chain. ( P. 69) 9.20 Cleaning the chain Warning Danger of accident s Oil or grease on the tires redu ces their grip.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 70 – After drying, apply chai n spray. Offroad chain spray ( P. 170) 9.21 Checking the chain te nsion Warning Danger of accident s Danger caused by incor rect chain tension.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 71 100249-10 – Lean the motorcycle on t he side stand. – Shift gear to neutral. – Push the chain upward at a d istance from the chain s liding guard and determ ine the chain tension . Info The upper chain sectio n must be taut.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 72 100250-10 – Lean the motorcycle on t he side stand. – Shift gear to neutral. – Loosen nut . – Loosen nuts . – Adjust the chain tensio n by turning the adjusting sc rews left and right.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 73 9.23 Checking rear spro cket / engine sprocke t for wear 100132-10 – Check rear sprocket / e ngine sprocket for wea r. » If the rear sprocket / en gine sprocket are worn: – Replace rear sprock et / engine sprocket.
B 1 2 3 1 6 1 7 1 8 A MAINTENA NCE WORK O N CHASSIS AN D ENGINE 74 9.24 Checking chain wea r 400409-10 – Shift into neutral, pull the lo wer chain section with the sp ecified weight . Specification Weight of chain wear m easurement 15 kg (33 lb.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 75 9.25 Adjusting chain guid e x 100299-10 – Remove screws and . Take off the chain guide . Conditions Number of teeth: ≤ 4 4 teeth – Insert nut in hole . P osition the chain guide.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 76 400406-10 – Check the thickness of th e front and rear brake discs at s everal places on the disc to see if it conforms to measu rement . Info Wear reduces the thick ness of the brake disc aroun d the area used by the brake linings.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 77 100251-10 – Push the hand brake to the h andlebar and check free pl ay . Free play of hand brake lev er ≥ 3 mm ( ≥ 0.12 in) » If the free travel does n ot meet specifications : – Adjust the free travel o f the handbrake lever.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 78 9.29 Checking front brak e fluid level Warning Danger of accident s Brake system failure. – MIN If the brake fluid leve l falls below the MIN mark, thi s indicates a leakage in the b rake system or worn-out bra ke linings.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 79 Warning Skin irritations Bra ke fluid can cause skin irrita tion on contact. – Avoid contact with skin a nd eyes, and keep out of the rea ch of children. – If brake fluid gets into your e yes, rinse thoroughly with w ater and contact a doctor im mediately.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 80 100254-10 – Remove screws . – Remove cover with m embrane . – Add brake fluid to level . Specification Measurement of 5 mm (0.2 in) Brake fluid DOT 4 / D OT 5.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 81 9.32 Checking the front br ake linings Warning Danger of accident s Reduced braking due to w orn brake linings. – Worn brake linings sho uld be replaced immedia tely in an authorized KTM wo rkshop. Note Danger of accident s Reduced braking due to d amaged brake discs.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 82 Warning Skin irritations Bra ke fluid can cause skin irrita tion on contact. – Avoid contact with skin a nd eyes, and keep out of the rea ch of children. – If brake fluid gets into your e yes, rinse thoroughly with w ater and contact a doctor im mediately.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 83 100254-11 – Move the brake fluid rese rvoir mounted on the hand lebar to a horizontal positi on. – Remove screws . – Remove the cover wit h membrane . – Press the brake caliper b y hand on to the brake disc in orde r to press back the brake pistons.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 84 400418-10 – Check that leaf spring in the brake caliper and sli ding plate in the brake cal iper support are seated corr ectly. 100291-01 – Insert the brake pads , insert the bolt and moun t the split pin.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 85 9.34 Checking free play of f oot brake lever Warning Danger of accident s Brake system failure. – If there is no free travel on the fo ot brake pedal, pressure bu ilds up on the rear brake in the br ake system.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 86 100257-10 – Remove screw connec tion on foot brake cylind er . – To adjust the basic posit ion of the foot brake pedal as ne eded, loosen nut and tu rn screw accordingl y.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 87 Warning Danger of accident s Reduced braking due to o ld brake fluid. – Have the front and rear bra ke fluid replaced accordi ng to the service plan in an auth orized KTM workshop. 100258-10 – Stand the vehicle uprig ht.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 88 Warning Danger of accident s Reduced braking due to o ld brake fluid. – Have the front and rear bra ke fluid replaced accordi ng to the service plan in an auth orized KTM workshop. Warning Environmental ha zard Problem materia ls cause environmenta l damage.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 89 9.38 Checking the rear bra ke linings Warning Danger of accident s Reduced braking due to w orn brake linings. – Worn brake linings sho uld be replaced immedia tely in an authorized KTM wo rkshop. Note Danger of accident s Reduced braking due to d amaged brake discs.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 90 Warning Skin irritations Bra ke fluid can cause skin irrita tion on contact. – Avoid contact with skin a nd eyes, and keep out of the rea ch of children. – If brake fluid gets into your e yes, rinse thoroughly with w ater and contact a doctor im mediately.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 91 100259-10 – Stand the vehicle uprig ht. – Remove screw cover w ith membrane . – Press the brake caliper b y hand on to the brake disc in orde r to press back the brake piston.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 92 100289-01 – Insert the brake pads , insert the bolt and moun t the split pin. – Operate the foot brake lev er repeatedly until the brak e linings lie on the brake disc a nd there is a tight spot. – Adjust the brake fluid lev el to the MAX mark.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 93 100262-10 – Remove screw . – Loosen screw . 100263-10 – Holding the front whe el, withdraw the wheel sp indle. Take the front wh eel out of the fork. Info Do not pull the hand brake le ver when the front wheel is rem oved.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 94 9.41 Fitting front wheel x Warning Danger of accident s Reduced braking due to o il or grease on the brake discs . – Always keep the brake di scs free of oil and grease, and c lean them with brake clean er when necessary.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 95 – Fully tighten screw . Specification Screw, fork stub M8 15 Nm (11.1 lbf ft) 9.42 Removing rear whe el x – Jack up the motorcycle . ( P. 56) 100267-10 – Press the brake caliper b y hand on to the brake disc in orde r to press back the brake piston.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 96 9.43 Fitting rear wheel x Warning Danger of accident s Reduced braking due to o il or grease on the brake discs . – Always keep the brake di scs free of oil and grease, and c lean them with brake clean er when necessary.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 97 100270-10 – Push the rear wheel forwa rd as far as possible and place t he chain on the rear sprocke t. – Mount the wheel spin dle, chain adjuster and n ut.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 98 100271-10 – Check rubber damper s of the rear hub for damage a nd wear. » If the rubber dampers of th e rear hub are damaged or worn : – Change all rubber damp ers in the rear hub.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 99 Warning Danger of crashing Impairment of riding beha vior due to different tire trea d patterns on front and rear wh eels. – The front and rear wheels m ust be fitted with tires with sim ilar tread patterns to preve nt loss of control over the vehi cle.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 100 – Check the depth of the trea d. Info Note local national reg ulations concerning the m inimum tread depth. Minimum tread depth ≥ 2 mm ( ≥ 0.08 in) » If the minimum tread dep th is insufficient: – Change the tires.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 101 – Check tire air pressure wh en tires are cold. Tire air pressure, offro ad, single rider front 1.5 bar (22 ps i) Rear 1.5 bar (22 ps i) Tire air pressure, road , solo front 1.8 bar (26 ps i) Rear 1.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 102 100275-01 – To check spoke tensio n, tap each spoke with a screw driver. Specification You should hear a high not e.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 103 9.49 Mounting the seat 100276-10 – Hook slot of the seat onto s crew , press the rear do wnward and at the same time push it forward. – Push locking pin into lo ck housing and push the b ack of the seat down until the locking pin locks in plac e with an audible click.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 104 100277-10 – Disconnect the negat ive (minus) cable of the batte ry. – Pull off connector in a n upward direction. – Remove screws . – Pull retaining bracket of the battery forward and re move it.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 105 – Set the clock. ( P. 29) 9.52 Recharging the batt ery x Warning Risk of injury Batter y acid and battery gases cau se serious cauterizati on. – Keep batteries out of the re ach of children. – Wear suitable protect ive clothing and goggles .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 106 Info Even if there is no load on the ba ttery, it loses power every da y. The charge state and the ty pe of charge are very import ant for the service life of the bat tery. Fast recharging with a hig h charge current shorten s the battery's service life .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 107 100151-10 – Connect the battery cha rger to the battery. Switch on th e battery charger. Battery charger (584 29074000) You can also use the batte ry charger to test rest potenti al and start potential of the ba t- tery, and to test the genera tor.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 108 Info The main fuse protects a ll power-consuming com ponents of the vehicle. It is l ocated in the housing of the el ectric starter relay next to the battery. – Switch off all power-con suming components an d switch off the engine.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 109 – Attach the protection co vers. – Mount the seat. ( P. 103) – Set the clock. ( P. 29) 9.54 Changing fuses of in dividual power consu mers Info The fuse box containin g the fuses of individual pow er consumers is located u nder the seat.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 110 600606-10 – Remove defective fus e. Specification Fuse 1 - 10A - ignition, co mbination instrume nt, alarm system (optio nal) Fuse 2 - 10A - clo.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 111 Warning Fire hazard The elec trical system can be over loaded by the use of incorrec t fuses. – Use only fuses with the pre scribed amperage. Ne ver by-pass or repair fuses . – Use spare fuses with the c orrect rating only.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 112 100237-10 – Pull the Map ‑ Select sw itch and holder upward o ff of the retaining bracket. – Pull the Map ‑ Select sw itch out of the holder. 100238-10 – Turn the adjusting whee l until the desired digit is next to m arking .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 113 9.56 Removing headlig ht mask with headlight – Switch off all power-con suming components an d switch off the engine. 600607-10 – Protect the fender again st damage by covering it wit h a cloth. – Remove the screws o n the left and right.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 114 9.57 Refitting the headlig ht mask with the headligh t 100294-11 – Connect the connecto rs of headlight and flas her lights .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 115 100296-10 – Position brake-hose g uide . Mount and tight en screws . Specification Remaining screws, ch assis M6 10 Nm (7.4 lbf ft) 9.58 Changing the headl ight bulb Note Damage to reflector Keep the glass of the bulb fre e of grease.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 116 600611-10 – Detach spring bar . – Remove headlight bu lb . – Insert a new headlight bu lb into the headlight housi ng. Headlight (H4/P43 t) ( P. 158) – Fit the headlight bulb in the h eadlight using the spring b ar.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 117 600612-10 – Pull bulb socket out of t he reflector. – Pull parking light bulb out of the bulb socket. – Check parts for damage a nd wear. Replace damag ed or worn parts. – Insert a new parking ligh t bulb into the bulb socket.
0 0 B B 0 0 A A MAINTENA NCE WORK O N CHASSIS AN D ENGINE 118 – Press the new flasher bu lb carefully into the holder an d turn it clockwise as far as it will go. Flasher light (BA15s ) ( P. 158) – Mount the orange cap. – Position the diffuser.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 119 9.62 Adjusting the headlig ht range – Check the headlamp se tting. ( P. 118) 600613-01 – Use a screwdriver (see il lustration) to adjust the hea dlight range.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 120 100286-10 Note Engine failure Un filtered intake air has a nega tive effect on the service life o f the engine. – Never ride the vehicle wi thout an air filter since dust an d dirt can get into the engine and result in incre ased wear.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 121 100285-11 – Mount and tighten scre ws . Specification Remaining screws, ch assis M6 10 Nm (7.4 lbf ft) – Mount the seat. ( P. 103) 9.65 Cooling system 600614-10 The water pump in the en gine forces the coolant to fl ow.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 122 400407-10 The coolant is cooled by th e air stream and a radiator fan , which is controlled by a th er- moswitch. The lower the speed, the le ss the cooling effect. Dirty co oling fins also reduce the c ooling effect.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 123 100283-10 Condition Engine is cold. – Stand the motorcycle o n its side stand on a horizonta l surface.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 124 100284-10 – Screw off the radiator c ap . – Check antifreeze of coo lant. − 25… − 45 °C ( − 13… − 49 °F) » If the antifreeze of the coo ling liquid does not meet spe cifications: – Correct antifreeze of c oolant.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 125 Warning Danger of poisoning Coolants are poisonou s and a health hazard. – Avoid contact betwee n coolants and skin, eyes an d clothing. If fuel gets into yo ur eyes, rinse immediate ly with water and con- tact a doctor.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 126 100284-10 – Screw off the radiator c ap and check the coola nt level in the radiator. The radiator must be com pletely full. » If the level of the cooling liq uid does not meet specific ations: – Correct the coolant leve l and find out the cause of the los s.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 127 600616-10 – Stand the vehicle uprig ht. – Place a suitable contai ner under the engine. – Remove screw . Re move the radiator cap. – Completely drain the co olant. – Fit screw with a new sea l and tighten it.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 128 600619-10 – Refill the coolant. Alternative 1 Coolant ( P. 166) Alternative 2 Coolant (mixed ready to u se) ( P.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 129 9.70 Adjusting basic posit ion of clutch lever Info Turn the adjusting scre w clockwise to increase th e distance between the clu tch lever and the handleba r. Turn the adjusting scre w counterclockwise to de crease the distance bet ween the clutch lever and the h andlebar.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 130 100281-10 – Remove screws . – Remove the cover wit h membrane . – Check the fluid level. Fluid level under top le vel of container. 4 mm (0.16 in) » If the fluid level does n ot meet specifications : – Correct the fluid level of the h ydraulic clutch.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 131 Danger Danger of poisoning Exhaust gases are pois onous and can result in unconsciousness a nd/or death. – When running the engin e, always make sure there is s ufficient ventilation, and do not start or run the engi ne in a closed space.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 132 9.74 Removing the engin e guard – Stand the motorcycle o n its side stand on a horizonta l surface. 100198-10 – Remove screws on th e left and right. – Pull the engine guard forw ard out of the holders and set it do wn.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 133 9.76 Checking engine oil l evel Info The engine oil level mus t be checked when the engin e is at operating temperatu re. – Stand the motorcycle u pright on a horizontal surfa ce. 100210-10 Condition The engine is at operatin g temperature.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 134 9.78 Draining engine oil x Warning Danger of scalding Engine oil and gear oil get ver y hot when the motocycle is d riven. – Wear suitable protect ive clothing and gloves. If yo u scald yourself, hold the a ffected area under cold wat er immediately.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 135 100201-01 – Thoroughly clean the o il drain plug with a magnet. – Check parts for damage a nd wear. Replace damag ed or worn parts. – Refit the oil drain plug w ith the magnet and seal ring an d tighten it.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 136 100202-10 – Remove screws . R emove oil filter cover with O-ring. – Pull the oil filter insert out of the oil filter casin g. Circlip pliers reverse (5 1012011000) 100203-10 – Remove screws .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 137 9.80 Mounting oil filter x 100204-10 – Check parts for damage a nd wear. Replace damag ed or worn parts. – Insert oil filter and . – Oil the O-rings of the oil fi lter cover. Refit the oil filte r cover and .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 138 100205-10 – Remove the plug with t he oil screen and O-rings . 100206-10 – Remove the plug with t he oil screen and O-rings . – Drain the remaining eng ine oil. – Thoroughly clean par ts and sealing area.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 139 100208-10 – Position oil screen wi th O-rings. – Refit plug with O-ring a nd tighten it.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 140 9.83 Topping up engine oil Info Too little engine oil or poor -quality engine oil results i n premature wear to the engi ne. 100209-10 – Remove filler plug with O- ring from the clutch cov er and add engine oil.
TROUBLES HOOTING 141 10 TROUBLESHOOTING Faults Possible cause Action Engine does not turn whe n the electric starter button is presse d Operating error – Carry out the instruction s for starting. ( P. 43) Battery discharged – Recharge the battery.
TROUBLES HOOTING 142 Faults Possible cause Action Engine has too little powe r. Fuel filter very dirty – Have the fuel filter changed. Defect in fuel injection sy stem – Read the error memory wi th the KTM diagnostics tool and co rrect the fault. Engine overheats.
TROUBLES HOOTING 143 Faults Possible cause Action Headlight and parki ng light not functioning Fuse 7 blown – Change th e fuses of individual powe r consumers. ( P. 109) Flasher light, brake ligh t and horn not functioning Fuse 6 blown – Change th e fuses of individual powe r consumers.
FLASHING C ODE 144 11 FLASHING CODE Fault Description Possible cause Action 02 FI warning lamp ( MI L ) flashes briefly 2x Malfunction in ignitio n pulse generator circuit – Check the ignition puls e generator.
FLASHING C ODE 145 Fault Description Possible cause Action 27 FI warning lamp ( MI L ) flashes 2x long, 7x short Malfunction in voltag e supply circuit of throttle valve co ntrol unit – Check the throttle valve c on- trol unit voltage supp ly.
FLASHING C ODE 146 Fault Description Possible cause Action 91 FI warning lamp ( MI L ) flashes 9x long, 1x short Malfunction in CAN bus c om- munication – Check CAN bus commu nica- tion.
CLEANING 14 7 12 CLEANING 12.1 Cleaning motorcyc le Note Material damage Damage and destructio n of components by high-p ressure cleaning equip ment.
CLEANING 14 8 Warning Danger of accident s Reduced braking due to w et or dirty brakes. – Clean or dry dirty or wet brake s by riding and braking gent ly. – After cleaning, ride the ve hicle a short distance unti l the engine warms up, and the n apply the brakes.
CONSERV ATION FOR WI NTER OPERA TION 149 13 CONSERVATION FOR WI NTER OPERATION 13.1 Conservation for wi nter operation Info If you use the motorcycle i n winter, you must expect sa lt on the roads. You should the refore take precautions a gainst aggressive road salt.
STORAGE 150 14 STORAGE 14.1 Storage Info If you want to garage the mot orcycle for a longer period, ta ke the following actions . Before storing the moto rcycle, check all parts for fun ction and wear. If service, re pairs or replacements ar e necessary, you should do this during the storage p eriod (less workshop ove rload).
STORAGE 151 – Cover the motorcycle w ith a porous sheet or blanket . Info Do not use non-porous m aterials since they preve nt humidity from escapin g, thus causing corrosio n.
TECHNICA L DATA - ENGINE 152 15 TECHNICAL DATA - ENGIN E Design 1-cyliner 4-stroke en gine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in ) Bore 102 mm (4.02 in ) Compression ratio 11,8:1 Control OHC, 4 valves controlle d via rocker arm, chain drive Valve diameter, intak e 40 mm (1.
TECHNICA L DATA - ENGINE 153 6th gear 23:20 Mixture preparation Electronic fuel injecti on Ignition Contactless control led fully electronic ignitio n with digital ignition adjustment Generator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 spark plug electrode ga p 0.
TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 154 16 TECHNICAL DATA - ENGINE T IGHTENING TORQUES Plug, oil bore self-tapping 9 Nm (6.6 lbf ft) Loct ite ® 243™ Screw, membrane fixa tion M3 2.5 Nm (1.84 lbf ft) L octite ® 243™ Oil jet, conrod lubrica tion M4 2 Nm (1.
TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 155 Screw, engine housin g M6 10 Nm (7.4 lbf ft) – Screw, shift drum loca ting M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctit e ® 222 Screw, timing chain ten sioning rail M6 10 Nm (7.
TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 156 Screw, cylinder head M10 Tightening sequence: Tighten diagonally, b eginning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.
TECHNICA L DATA - CHASS IS 157 17 TECHNICAL DATA - CHAS SIS Frame Lattice frame made of ch rome molybdenum stee l tubing, powder- coated Fork WP 4860 MXMA Shock absorber WP Suspension 461 8 with Pro ‑ Lever deflector Suspension travel front 250 mm (9.
TECHNICA L DATA - CHASS IS 158 Rear wheel gearing 15:45 Chain 5/8 x 1/4” X ‑ rin g Steering head angle 63° Wheelbase 1,498±1 5 mm (58.98±0.59 in) Seat height unloade d 910 mm (35.83 in) Ground clearance unl oaded 300 mm (11.
TECHNICA L DATA - CHASS IS 159 Brake / tail light LED Licence plate lamp W2,1x9,5d 12 V 5 W Front tire Rear tire 90/90 - 21 54 H TL Metzeler Enduro 3 Sahara 140/80 - 18 70 H TL Metzeler Enduro 3 Sahara For further information , see the Service section un der: http://www.
TECHNICA L DATA - FORK 160 18 TECHNICAL DATA - FORK Fork part number 14.18.7D.11 Fork WP 4860 MXMA Compression damp ing Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10.
TECHNICA L DATA - SHOCK A BSORBER 161 19 TECHNICAL DATA - SHOCK AB SORBER Shock absorber part n umber 15.18.7D.11 Shock absorber WP Suspension 461 8 with Pro ‑ Lever deflector Compression damp ing, high-speed Comfort 2 turns Standard 1.
TECHNICA L DATA - SHOCK A BSORBER 162 Fitted length 395 mm (15.55 in ).
TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 163 20 TECHNICAL DATA - CHASSIS T IGHTENING TORQUES Remaining screws, ch assis M5 4 Nm (3 lbf ft) – Spoke nipple, front wh eel M5 4 Nm (3 lbf ft) – Spoke nipple, rear wh eel M5 4 Nm (3 lbf ft) – Screw, exhaust heat s hield M5 8 Nm (5.
TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 164 Screw, magnetic hold er on side stand M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, voltage regula tor/rectifier M6 8 Nm (5.9 lbf ft) – Screw, SLS valve M 6 4 Nm (3 lbf ft) – Screw, ignition lock M6 10 Nm (7.
TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 165 Screw, handlebar cla mp M8 20 Nm (14.8 lbf ft) Loctit e ® 243™ Screw, side stand brack et M8 25 Nm (18.4 lbf ft) – Screw, connection lev er on frame M8 30 Nm (22.1 lbf ft) – Remaining nuts, chas sis M1 0 50 Nm (36.
SUBSTAN CES 166 21 SUBSTANCES Brake fluid DOT 4 / D OT 5.1 according to – DOT Specification – Use only brake fluid that c omplies with the specifie d standards (see specifi cations on the container) a nd that possesses the cor re- sponding properties .
SUBSTAN CES 167 Engine oil (SAE 10W /60) according to – JASO T903 MA ( P. 171) – SAE ( P. 171) (SAE 10W/60) Specification – Use only engine oils tha t comply with the specified s tandards (see specific ations on the container) an d that possess the corresp onding properties.
SUBSTAN CES 168 Specification – Use only hydraulic flui d that complies with the spec ified standards (see spe cifications on the contai ner) and that possesses th e corre- sponding properties .
AUXILIARY S UBSTANC ES 169 22 AUXILIARY SUBSTANCES Chain cleaner Specification – KTM recommends M otorex ® products. Supplier Motorex ® – Chain Clean 611 Cleaning and polish ing materials for metal, r ubber and plastic Specification – KTM recommends M otorex ® products.
AUXILIARY S UBSTANC ES 170 Long-life grease Specification – KTM recommends M otorex ® products. Supplier Motorex ® – Long Therm 2000 Motorcycle cleane r Specification – KTM recommends M otorex ® products.
STANDAR DS 171 23 STANDARDS JASO T903 MA Different technical de velopment directions re quired a new specificat ion for 4-stroke motorcyc les – the JASO T903 MA Stan dard. Ear- lier, engine oils from the au tomobile industry were u sed for 4-stroke motorcy cles because there was no s eparate motorcycle sp ecification.
INDEX 172 INDEX A Air filter f i t t i n g .................................... 1 2 0 r e m o v i n g .................................. 1 1 9 Antifreeze c h e c k i n g .................................. 1 2 2 B Baggage ..............................
INDEX 173 Setting/resetting TRIP 1 d i s p l a y ................... 3 0 Setting/resetting TRIP 2 d i s p l a y ................... 3 1 S p e e dd i s p l a y ............................... 2 8 T a c h o m e t e r ....................
INDEX 174 Fork part number ................................ 1 8 Fork protector p o s i t i o n i n g ................................. 6 4 r e m o v e .................................... 6 4 Front wheel f i t t i n g .................................
INDEX 175 Oil screens c l e a n i n g .................................. 1 3 7 OWNER'S MANUAL B a s i c s ..................................... 1 0 P Parking ...................................... 4 9 Parking light bulb c h a n g i n g ..........
INDEX 176 Technical data C h a s s i s ............................... 1 5 7 - 1 5 9 Chassis tightening torqu es . . . . . . . . . . . . . . . . . . 163-165 E n g i n e ............................... 1 5 2 - 1 5 3 Engine tightening torque s . . . . .
KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 03/2008 Photo Mitterbauer *32112 39en* 3211239en.
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If you already are a holder of KTM 690 ENDURO EU, 690 ENDURO AUS/UK, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 690 ENDURO EU, 690 ENDURO AUS/UK.
However, one of the most important roles played by the user manual is to help in solving problems with KTM 690 ENDURO EU, 690 ENDURO AUS/UK. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 690 ENDURO EU, 690 ENDURO AUS/UK along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
