KTM 690 Enduro R 2009 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2009 Vehicle Type: Dual-Sport Motorcycle Codes Chassis Code Prefix: KTM 690 👋 Introduction Market Position Vehicle Segment: Lightweight dual-sport motorcycle, positioned for off-road capability with street legality Target Audience: Adventure riders, off-road enthusiasts, riders seeking a versatile and capable lightweight dual-sport Competitive Analysis Key Competitors: BMW G 450 X, Husqvarna TE series, Honda CRF series, Yamaha WRR series Key Features Vehicle Strengths: Lightweight chassis, powerful single-cylinder engine, long-travel suspension, off-road prowess, KTM's performance heritage Manual Value Proposition Manual Benefit: Enables owners and technicians to perform all necessary maintenance, repairs, and diagnostics accurately and efficiently, saving time and money. Professional Standard: Covers the same information used by KTM certified technicians. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, and maintenance Secondary Coverage: Troubleshooting, diagnostics, specifications Page Count Estimated Page Count: Over 300 pages (typical for comprehensive workshop manuals) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top end, bottom end, cooling system, lubrication system, fuel injection, ignition system, exhaust system Transmission: Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication Chassis: Frame, subframe, swingarm, linkages, bearings Suspension: Front fork (WP USD) disassembly, service, and adjustment; Rear shock absorber service and adjustment Brakes: Front and rear brake system (Brembo), hydraulic lines, calipers, master cylinders, bleeding procedures, rotor specifications Electrical: Wiring diagrams, starter system, charging system (alternator, regulator/rectifier), lighting, instruments, ECU, sensors, battery Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, injector servicing Bodywork: Fairings, fenders, seat, fuel tank cover removal and installation Wheels And Tires: Wheel bearing replacement, tire mounting and balancing, spoke tensioning Procedures Included Preventative Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting Repair Procedures: Step-by-step instructions for component disassembly, overhaul, and reassembly Technical Specifications: Torque values, clearances, tolerances, fluid capacities, electrical resistance values Technical Depth Depth Of Coverage: Comprehensive; covers everything from routine maintenance to full engine rebuilds and advanced diagnostics. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, suitable for printing at home or a print shop Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, SOHC, four valves per cylinder Displacement: 657.4 cc (657cc) Bore X Stroke: 102 mm x 80 mm Cooling System: Liquid-cooled Compression Ratio: 12.3:1 Valve Actuation: Rocker arm actuated valves Exhaust System: Under-seat exhaust system Performance Claimed Horsepower: Approx. 60 HP (45 kW) @ 7500 rpm (Varies slightly by region/spec) Claimed Torque: Approx. 47.9 lb-ft (65 Nm) @ 6000 rpm (Varies slightly by region/spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Keihin throttle body Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/95 ROZ Lubrication System Oil Type Recommendation: Fully synthetic motorcycle oil, SAE 10W-50 (refer to manual for exact specification) Oil Capacity With Filter: Approx. 1.7 Liters (1.8 US qt) 🔧 Transmission Standard Transmission Type: 6-speed, claw-shifted Features Clutch Type: Hydraulically operated APTC slipper clutch (Adler Power Torque Clutch) Final Drive: Chain drive, 520 O-ring chain Transmission Fluid Transmission Oil Type: Gear oil, SAE 75W/80 (API GL 4 or GL 5) Transmission Oil Capacity: Approx. 0.8 Liters (0.85 US qt) 📐 Dimensions Exterior Wheelbase: Approx. 1500 mm +/- 15 mm (59.06 in +/- 0.59 in) Seat Height: Approx. 925 mm (36.42 in) Weights Dry Weight: Approx. 146 kg (321.9 lbs) Fuel Tank Capacity: Approx. 12 Liters (3.17 US gal), including approx. 1.5 Liters reserve Wheels And Tires Front Tire Size: 90/90-21 Rear Tire Size: 140/80-18 Front Wheel Type: Spoked, 21 x 1.60 Rear Wheel Type: Spoked, 18 x 2.50 🛡️ Safety Features Ratings ABS: Optional (check specific model configuration) Active Features Braking System Front: Disc brake, 300 mm diameter, 4-piston radial fixed caliper (Brembo) Braking System Rear: Disc brake, 240 mm diameter, 2-piston fixed caliper (Brembo) Passive Features Lighting: Halogen headlight, LED taillight Instrumentation: Digital instrument cluster with tachometer, speedometer, odometer, trip meters, fuel level indicator 💡 Technology Features Infotainment Infotainment System: N/A (Focus is on performance and off-road capability, not complex infotainment) Driver Assistance Rider Aids: Optional ABS (Anti-lock Braking System) system, typically switchable between road and off-road modes. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,100 miles) or annually, whichever comes first (refer to manual for exact spec) Oil Filter Replacement Interval: Every 5,000 km (3,100 miles) or annually Air Filter Cleaning Interval: Every 5,000 km (3,100 miles) or as needed based on riding conditions Spark Plug Replacement Interval: Every 10,000 km (6,200 miles) or annually Chain Adjustment And Lubrication Interval: Regularly, every 500-1000 km (300-600 miles) or after off-road riding Valve Clearance Check Interval: Every...
Fully synthetic motorcycle oil, SAE 10W-50 (refer to manual for exact specification)
Oil Capacity With Filter:
Approx. 1.7 Liters (1.8 US qt)
🔧 Transmission
Standard
Transmission Type:
6-speed, claw-shifted
Features
Clutch Type:
Hydraulically operated APTC slipper clutch (Adler Power Torque Clutch)
Final Drive:
Chain drive, 520 O-ring chain
Transmission Fluid
Transmission Oil Type:
Gear oil, SAE 75W/80 (API GL 4 or GL 5)
Transmission Oil Capacity:
Approx. 0.8 Liters (0.85 US qt)
📐 Dimensions
Exterior
Wheelbase:
Approx. 1500 mm +/- 15 mm (59.06 in +/- 0.59 in)
Seat Height:
Approx. 925 mm (36.42 in)
Weights
Dry Weight:
Approx. 146 kg (321.9 lbs)
Fuel Tank Capacity:
Approx. 12 Liters (3.17 US gal), including approx. 1.5 Liters reserve
Wheels And Tires
Front Tire Size:
90/90-21
Rear Tire Size:
140/80-18
Front Wheel Type:
Spoked, 21 x 1.60
Rear Wheel Type:
Spoked, 18 x 2.50
🛡️ Safety Features
Ratings
ABS:
Optional (check specific model configuration)
Active Features
Braking System Front:
Disc brake, 300 mm diameter, 4-piston radial fixed caliper (Brembo)
Braking System Rear:
Disc brake, 240 mm diameter, 2-piston fixed caliper (Brembo)
Passive Features
Lighting:
Halogen headlight, LED taillight
Instrumentation:
Digital instrument cluster with tachometer, speedometer, odometer, trip meters, fuel level indicator
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus is on performance and off-road capability, not complex infotainment)
Driver Assistance
Rider Aids:
Optional ABS (Anti-lock Braking System) system, typically switchable between road and off-road modes.
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,100 miles) or annually, whichever comes first (refer to manual for exact spec)
Oil Filter Replacement Interval:
Every 5,000 km (3,100 miles) or annually
Air Filter Cleaning Interval:
Every 5,000 km (3,100 miles) or as needed based on riding conditions
Spark Plug Replacement Interval:
Every 10,000 km (6,200 miles) or annually
Chain Adjustment And Lubrication Interval:
Regularly, every 500-1000 km (300-600 miles) or after off-road riding
Valve Clearance Check Interval:
Every 10,000 km (6,200 miles)
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, mixture 50% with distilled water (refer to manual for exact specification)
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Potential Engine Considerations:
While robust, the LC4 engine can benefit from diligent maintenance. Some early models experienced fuel pump issues, but improvements were made.
Suspension Maintenance:
Regular servicing of WP suspension components is crucial for optimal performance and longevity, especially with off-road use.
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM is renowned for its 'Ready to Race' philosophy and dominance in off-road racing (motocross, enduro, rally raid).
Model Evolution
Predecessors:
Built upon KTM's experience with previous LC4 and Enduro models, refining the platform for increased versatility and performance.
Key Updates 2009:
Refinements to engine management, chassis components, and suspension tuning compared to earlier models.
Production
Manufacturing Location:
Austria
🏆 Awards & Recognition
Recognitions
Industry Standing:
KTM motorcycles are consistently recognized for their performance, build quality, and off-road dominance. The 690 Enduro R is widely praised for its blend of off-road capability and street usability.
Ratings
Motorcycle Reviews:
Highly rated by motorcycle publications for its power, handling, and off-road performance in its class.
Certifications
Emissions Standards:
Meets relevant emissions standards for its model year.
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