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KTM 690 Enduro R 2009 Service Repair Workshop Manual

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The 2009 KTM 690 Enduro R is a lightweight dual-sport motorcycle engineered for adventure riders and off-road enthusiasts. Building upon KTM's extensive racing heritage, this model offers exceptional off-road prowess combined with street legality, making it a versatile choice for a wide range of riding conditions. Its design emphasizes a lightweight chassis, a powerful single-cylinder engine known for its performance, and long-travel suspension, all contributing to its renowned handling and capability. The 690 Enduro R is recognized for its robust build quality and its ability to tackle challenging terrains while remaining comfortable for longer journeys. This comprehensive workshop service repair manual provides detailed information for the complete service, repair, and maintenance of your 2009 KTM 690 Enduro R. It covers all essential systems, including the engine, transmission, chassis, suspension, brakes, and electrical components, offering step-by-step procedures for everything from routine maintenance like oil changes to complex overhauls and diagnostics. The manual also includes critical technical specifications, troubleshooting guides, and safety information, ensuring that owners and technicians can maintain the vehicle accurately and efficiently. This resource is designed to help you keep your KTM 690 Enduro R in optimal condition, mirroring the standards used by KTM certified technicians. 🏷️ 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...
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KTM 690 Enduro R 2009 Service Repair Workshop ManualKTM 690 Enduro R 2009 Service Repair Workshop ManualKTM 690 Enduro R 2009 Service Repair Workshop ManualKTM 690 Enduro R 2009 Service Repair Workshop Manual
The 2009 KTM 690 Enduro R is a lightweight dual-sport motorcycle engineered for adventure riders and off-road enthusiasts. Building upon KTM's extensive racing heritage, this model offers exceptional off-road prowess combined with street legality, making it a versatile choice for a wide range of riding conditions. Its design emphasizes a lightweight chassis, a powerful single-cylinder engine known for its performance, and long-travel suspension, all contributing to its renowned handling and capability. The 690 Enduro R is recognized for its robust build quality and its ability to tackle challenging terrains while remaining comfortable for longer journeys. This comprehensive workshop service repair manual provides detailed information for the complete service, repair, and maintenance of your 2009 KTM 690 Enduro R. It covers all essential systems, including the engine, transmission, chassis, suspension, brakes, and electrical components, offering step-by-step procedures for everything from routine maintenance like oil changes to complex overhauls and diagnostics. The manual also includes critical technical specifications, troubleshooting guides, and safety information, ensuring that owners and technicians can maintain the vehicle accurately and efficiently. This resource is designed to help you keep your KTM 690 Enduro R in optimal condition, mirroring the standards used by KTM certified technicians.
🏷️ 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 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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