KTM 690 Enduro R 2009 Workshop Repair Service Manual
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The 2009 690 Enduro R is a versatile dual-sport motorcycle engineered for adventure riders and off-road enthusiasts. Building on a strong heritage in off-road racing, this model features a powerful single-cylinder LC4 engine known for its robust torque, long-travel suspension for exceptional off-road capability, and a lightweight, agile chassis. Its design prioritizes performance and handling, making it a capable machine for both challenging trails and street legality, positioning it as a strong contender in the dual-sport market. This workshop repair service manual provides comprehensive guidance for maintaining and repairing the 2009 690 Enduro R. It covers all essential aspects, including detailed engine disassembly and assembly, transmission and clutch service, fuel injection system diagnostics, electrical system troubleshooting with wiring diagrams, and suspension and brake system maintenance. The manual also includes routine maintenance procedures, component replacement guides, and troubleshooting tips for common issues, making it an indispensable resource for owners and technicians alike. 🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2009 Product Type: Workshop Repair Service Manual Codes Chassis Code Variant: 690 Enduro R (likely specific internal codes may exist within manual) 👋 Introduction Market Position Category: Dual-sport motorcycle, designed for off-road capability with street legality. Target Audience: Adventure riders, off-road enthusiasts, and those seeking a capable dual-purpose machine. Competitive Analysis Competitors 2009: BMW G 650GS, Kawasaki KLR650, Suzuki DR650SE, Honda XR650L. Key Features Feature 1: Powerful single-cylinder engine (LC4) known for strong torque. Feature 2: Long-travel suspension for off-road prowess. Feature 3: Lightweight chassis and agile handling. Feature 4: ABS braking system (likely selectable). 📋 Manual Details Coverage Areas Model Coverage: All Models/Engines/Trim/Transmissions for the 2009 KTM 690 Enduro R Page Count Estimated Pages: Detailed page count not explicitly stated in product info, but workshop manuals are typically extensive (e.g., 400-800+ pages). Manual Type Type: Workshop Repair Service Manual Language Language: English (highly probable for a professional workshop manual). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and troubleshooting for the LC4 engine family. Transmission Clutch: Gearbox operation, maintenance, repair, clutch service, and hydraulic systems. Fuel System: Fuel injection system diagnostics, maintenance, injector servicing, fuel pump, and fuel tank. Electrical System: Ignition system, battery, charging system, lighting, starter motor, ECU, wiring diagrams, and sensor troubleshooting. Suspension Steering: Front fork (WP Suspension) disassembly, seal replacement, oil changes, rear shock absorber service, steering head bearing maintenance. Brakes: Brake system maintenance (front and rear discs/calipers), hydraulic system bleeding, pad replacement, fluid specifications. Cooling System: Radiator, coolant hoses, fan operation, coolant type and capacity. Exhaust System: Exhaust component inspection, gasket replacement, and potential tuning considerations. Bodywork Chassis: Frame inspection, plastic body panel removal/installation, seat, fuel tank mounting. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), chain adjustment, lubrication points, valve clearance checks. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable). Rebuilding: Complete engine rebuild procedures, including torque specifications for critical fasteners. Component Replacement: Step-by-step guides for replacing major components like wheel bearings, chain sprockets, brake lines, etc. Electrical Diagnostics: Wiring diagrams, continuity testing, voltage checks, and sensor testing. Technical Depth Depth: Comprehensive, from basic owner maintenance to advanced engine and electrical diagnostics, suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Type: PDF Searchability: Likely text-searchable PDF, allowing for quick information retrieval. Print Quality Quality: Professionally produced, typically featuring clear diagrams, illustrations, and text. Binding Type Type: N/A (Downloadable PDF) Paper Type Type: N/A (Downloadable PDF) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, 4-stroke, liquid-cooled, SOHC Displacement: 657.5 cc (657.5 cm3) Bore X Stroke: 102 mm x 80 mm Compression Ratio: 12.3:1 (approximate, verify with manual) Performance Horsepower: Approx. 60-65 HP (verify with manual for specific engine tune) Torque: Approx. 60-65 Nm (verify with manual for specific engine tune) Fuel System Type: Electronic fuel injection (EFI) with Keihin throttle body (e.g., 46mm) Fuel Type: Unleaded gasoline, minimum 95 octane (RON) Lubrication Oil Type: Semi-synthetic or fully synthetic motorcycle oil, SAE 10W/50 or 15W/50 (refer to manual for exact specification). Cooling System Coolant Type: Ethylene glycol-based coolant, pre-mixed 50/50 with distilled water. 🔧 Transmission Standard Type: 6-speed, sequential claw-shifted gearbox Clutch: APTC multi-disc wet clutch, hydraulically actuated Optional Type: N/A (standard configuration for this model) Features Features: Smooth engagement, wide gear ratios suitable for dual-sport use. Fluid Specifications Type: Motorcycle-specific gearbox oil or engine oil (refer to manual for confirmation of shared sump system and specific grade). 📐 Dimensions Exterior Seat Height: Approx. 900 mm (35.4 in) - typical for this type of bike. Ground Clearance: Approx. 270 mm (10.6 in) - indicates significant off-road capability. Weights Dry Weight: Approx. 145 kg (319.7 lbs) - dry weight, actual curb weight will be higher. Fuel Tank Capacity: Approx. 12 liters (3.17 US gal) - standard, aftermarket larger tanks are common. 🛡️ Safety Features Ratings ABS:...
The 2009 690 Enduro R is a versatile dual-sport motorcycle engineered for adventure riders and off-road enthusiasts. Building on a strong heritage in off-road racing, this model features a powerful single-cylinder LC4 engine known for its robust torque, long-travel suspension for exceptional off-road capability, and a lightweight, agile chassis. Its design prioritizes performance and handling, making it a capable machine for both challenging trails and street legality, positioning it as a strong contender in the dual-sport market.
This workshop repair service manual provides comprehensive guidance for maintaining and repairing the 2009 690 Enduro R. It covers all essential aspects, including detailed engine disassembly and assembly, transmission and clutch service, fuel injection system diagnostics, electrical system troubleshooting with wiring diagrams, and suspension and brake system maintenance. The manual also includes routine maintenance procedures, component replacement guides, and troubleshooting tips for common issues, making it an indispensable resource for owners and technicians alike.
🏷️ Basic Information
Identification
Make:
KTM
Model:
690 Enduro R
Year:
2009
Product Type:
Workshop Repair Service Manual
Codes
Chassis Code Variant:
690 Enduro R (likely specific internal codes may exist within manual)
👋 Introduction
Market Position
Category:
Dual-sport motorcycle, designed for off-road capability with street legality.
Target Audience:
Adventure riders, off-road enthusiasts, and those seeking a capable dual-purpose machine.
Competitive Analysis
Competitors 2009:
BMW G 650GS, Kawasaki KLR650, Suzuki DR650SE, Honda XR650L.
Key Features
Feature 1:
Powerful single-cylinder engine (LC4) known for strong torque.
Feature 2:
Long-travel suspension for off-road prowess.
Feature 3:
Lightweight chassis and agile handling.
Feature 4:
ABS braking system (likely selectable).
📋 Manual Details
Coverage Areas
Model Coverage:
All Models/Engines/Trim/Transmissions for the 2009 KTM 690 Enduro R
Page Count
Estimated Pages:
Detailed page count not explicitly stated in product info, but workshop manuals are typically extensive (e.g., 400-800+ pages).
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English (highly probable for a professional workshop manual).
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting for the LC4 engine family.
Transmission Clutch:
Gearbox operation, maintenance, repair, clutch service, and hydraulic systems.
Fuel System:
Fuel injection system diagnostics, maintenance, injector servicing, fuel pump, and fuel tank.
Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Rebuilding:
Complete engine rebuild procedures, including torque specifications for critical fasteners.
Component Replacement:
Step-by-step guides for replacing major components like wheel bearings, chain sprockets, brake lines, etc.
Electrical Diagnostics:
Wiring diagrams, continuity testing, voltage checks, and sensor testing.
Technical Depth
Depth:
Comprehensive, from basic owner maintenance to advanced engine and electrical diagnostics, suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick information retrieval.
Print Quality
Quality:
Professionally produced, typically featuring clear diagrams, illustrations, and text.
Binding Type
Type:
N/A (Downloadable PDF)
Paper Type
Type:
N/A (Downloadable PDF)
⚙️ Engine Specifications
Primary Engine
Type:
Single-cylinder, 4-stroke, liquid-cooled, SOHC
Displacement:
657.5 cc (657.5 cm3)
Bore X Stroke:
102 mm x 80 mm
Compression Ratio:
12.3:1 (approximate, verify with manual)
Performance
Horsepower:
Approx. 60-65 HP (verify with manual for specific engine tune)
Torque:
Approx. 60-65 Nm (verify with manual for specific engine tune)
Fuel System
Type:
Electronic fuel injection (EFI) with Keihin throttle body (e.g., 46mm)
Fuel Type:
Unleaded gasoline, minimum 95 octane (RON)
Lubrication
Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, SAE 10W/50 or 15W/50 (refer to manual for exact specification).
Cooling System
Coolant Type:
Ethylene glycol-based coolant, pre-mixed 50/50 with distilled water.
Smooth engagement, wide gear ratios suitable for dual-sport use.
Fluid Specifications
Type:
Motorcycle-specific gearbox oil or engine oil (refer to manual for confirmation of shared sump system and specific grade).
📐 Dimensions
Exterior
Seat Height:
Approx. 900 mm (35.4 in) - typical for this type of bike.
Ground Clearance:
Approx. 270 mm (10.6 in) - indicates significant off-road capability.
Weights
Dry Weight:
Approx. 145 kg (319.7 lbs) - dry weight, actual curb weight will be higher.
Fuel Tank Capacity:
Approx. 12 liters (3.17 US gal) - standard, aftermarket larger tanks are common.
🛡️ Safety Features
Ratings
ABS:
Standard on some models/markets, potentially switchable for off-road use. Manual will detail operation and maintenance.
Active Features
Braking System:
Front: Single disc, Brembo radial 4-piston caliper. Rear: Single disc, Brembo 2-piston caliper. ABS system.
Passive Features
Lighting:
Halogen headlight, LED taillight, standard turn signals.
💡 Technology Features
Infotainment
Dashboard:
Digital LCD display showing speed, RPM, odometer, trip meters, clock, and indicator lights. May include fuel level and gear position indicator.
Driver Assistance
ABS:
Anti-lock Braking System, likely with a mode for off-road use.
Connectivity
Connectivity:
N/A (basic motorcycle technology for this era).
🔧 Maintenance
Service Intervals
Oil Change:
Typically 5,000-7,500 km (3,000-4,500 miles) or annually, but the manual will provide precise intervals.
Air Filter:
Check every 5,000 km, clean/replace as needed. Off-road use may require more frequent attention.
Valve Clearance:
Initial check at 1,000 km, then every 10,000-15,000 km (manual will specify exact interval).
Fluid Specifications
Brake Fluid:
DOT 4 or DOT 5.1 (refer to manual for exact specification).
Coolant:
Ethylene glycol-based, pre-mixed 50/50 with distilled water.
Engine Oil Capacity:
Approx. 1.7-1.8 liters (refer to manual for exact capacity).
Known Issues
Common Issues:
Some early LC4 models experienced issues with fuel pump relays or intake boot cracking. Vibration at certain RPMs is inherent to single-cylinder engines. Manual will offer diagnostic solutions.
📚 Vehicle History
Brand Heritage
Heritage:
KTM has a strong heritage in off-road racing, particularly in motocross and rally raids, influencing their dual-sport designs.
Model Evolution
Evolution:
The 690 Enduro R represents KTM's evolution in the adventure/dual-sport segment, building on the legacy of their LC4 engine platform.
Production
Manufacturing Location:
Austria (KTM's primary manufacturing base).
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the 2009 model are not readily available, but the 690 Enduro R generally received positive reviews for its performance and off-road capability within its segment.
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