KTM 690 Enduro R 2010 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2010 Vehicle Type: Dual-Sport Motorcycle Codes Chassis Code: KTM 690 Enduro R (2010) Engine Code Prefix: LC4 👋 Introduction Market Position Segment: Lightweight, go-anywhere dual-sport motorcycle positioned for riders seeking off-road capability with street legality. Target Audience: Adventure riders, dual-sport enthusiasts, commuters seeking ruggedness and versatility, and off-road riders who need occasional street use. Competitive Analysis Key Competitors: BMW G 650 GS Sertão, Yamaha WR250R, Kawasaki KLR650, Honda CRF250L (though generally less off-road focused). Key Features Engine Characteristics: Torquey single-cylinder LC4 engine, known for its strong low-end and mid-range power delivery, suitable for both trail riding and highway cruising. Suspension And Chassis: Premium WP Suspension components offering excellent adjustability and travel for off-road prowess. Lightweight trellis frame. Ergonomics And Design: Designed for stand-up riding with ample ground clearance and rider triangle conducive to off-road control. Off Road Focus: Spoked wheels, robust bash plate, higher exhaust routing, and knobby-capable tires indicate a strong emphasis on off-road performance. 📋 Manual Details Coverage Areas Coverage: Complete factory service and repair coverage for the 2010 KTM 690 Enduro R. Page Count Page Count: Hundreds of pages (estimated 300-500 pages based on typical factory manuals of this scope). Manual Type Manual Type: Factory Service Repair Manual Language Language: English (assumed typical for international markets, confirmation required if other languages are critical). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine And Drivetrain: Complete engine disassembly, assembly, inspection, troubleshooting, and repair procedures for the LC4 engine. Includes fuel system, ignition, lubrication, cooling, and exhaust. Chassis And Suspension: Front forks (WP Suspension), rear shock absorber (WP Suspension), swingarm, linkage, steering head, wheel bearings, and frame inspection. Brakes: Front and rear brake system inspection, repair, bleeding, component replacement (calipers, master cylinders, lines, discs), and ABS system (if equipped). Electrical System: Wiring diagrams, component testing, battery, starter, alternator, lighting, sensors, ECU diagnosis, and instrument cluster. Fuel System: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), diagnostics, and adjustments. Bodywork And Ergonomics: Fairings, seat, fuel tank, fenders, handlebar, footpegs, and general cosmetic component removal and installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable via diagnostic tools). Major Repairs: Engine rebuilds, gearbox overhauls, suspension component overhauls, brake system overhauls, and electrical system repairs. Special Tools: Identification and usage of specialized tools required for specific repair and maintenance procedures. Technical Depth Depth: Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format PDF Quality: High-resolution, ensuring clarity of text, diagrams, and images. Searchable text for easy navigation. Print Quality Printability: Designed for full or partial printing, allowing users to create physical copies of specific sections or the entire manual. Binding Type Binding: N/A (Digital PDF format). Paper Type Paper Type: N/A (Digital PDF format). Completeness Content Scope: Complete, encompassing all aspects of the 2010 KTM 690 Enduro R as designed and serviced by the factory. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled, DOHC Displacement: 657.5 cc Bore X Stroke: 102 mm x 80 mm Compression Ratio: 12.3:1 (approx.) Performance Horsepower: Approx. 63 hp @ 7,500 rpm (Factory spec may vary slightly) Torque: Approx. 60 Nm (44.3 lb-ft) @ 6,000 rpm (Factory spec may vary slightly) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Keihin throttle body (typically 46mm) Fuel Type: Unleaded Gasoline (95 RON recommended) Lubrication Oil Capacity With Filter Change: Approx. 1.4 Liters (1.5 US qt) Recommended Oil Grade: SAE 10W-50 (or as per owner's manual, e.g., Motorex Power Synt 4T) Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0) 🔧 Transmission Standard Type: 6-speed, claw-shifted Clutch Type: Wet multi-disc clutch, hydraulically operated Features Final Drive: X-ring chain, 525 pitch Gear Ratios: Refer to manual for specific gear ratios (e.g., 1st: 32/14, 2nd: 30/17, 3rd: 28/19, 4th: 25/21, 5th: 22/23, 6th: 24/27) Transmission Oil Capacity: Approx. 1.1 Liters (1.16 US qt) Transmission Oil Grade: SAE 75W (or as per manual, often similar to engine oil grades for shared sump systems, but confirmation is vital) 📐 Dimensions Exterior Length: Approx. 2330 mm (91.7 in) Width Without Mirrors: Approx. 860 mm (33.9 in) Height Seat: Approx. 930 mm (36.6 in) Ground Clearance: Approx. 285 mm (11.2 in) Weights Dry Weight: Approx. 146 kg (321.9 lbs) Ready To Ride Weight Approx: Approx. 160 kg (352.7 lbs) (with all fluids, without rider) Gross Vehicle Weight Rating Gvwr: Refer to chassis plate or manual (typically around 300-350 kg) Wheels And Tires Front Wheel Size: 21 x 1.85 Rear Wheel Size: 18 x 2.50 Front...
Lightweight, go-anywhere dual-sport motorcycle positioned for riders seeking off-road capability with street legality.
Target Audience:
Adventure riders, dual-sport enthusiasts, commuters seeking ruggedness and versatility, and off-road riders who need occasional street use.
Competitive Analysis
Key Competitors:
BMW G 650 GS Sertão, Yamaha WR250R, Kawasaki KLR650, Honda CRF250L (though generally less off-road focused).
Key Features
Engine Characteristics:
Torquey single-cylinder LC4 engine, known for its strong low-end and mid-range power delivery, suitable for both trail riding and highway cruising.
Suspension And Chassis:
Premium WP Suspension components offering excellent adjustability and travel for off-road prowess. Lightweight trellis frame.
Ergonomics And Design:
Designed for stand-up riding with ample ground clearance and rider triangle conducive to off-road control.
Off Road Focus:
Spoked wheels, robust bash plate, higher exhaust routing, and knobby-capable tires indicate a strong emphasis on off-road performance.
📋 Manual Details
Coverage Areas
Coverage:
Complete factory service and repair coverage for the 2010 KTM 690 Enduro R.
Page Count
Page Count:
Hundreds of pages (estimated 300-500 pages based on typical factory manuals of this scope).
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English (assumed typical for international markets, confirmation required if other languages are critical).
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine And Drivetrain:
Complete engine disassembly, assembly, inspection, troubleshooting, and repair procedures for the LC4 engine. Includes fuel system, ignition, lubrication, cooling, and exhaust.
Chassis And Suspension:
Front forks (WP Suspension), rear shock absorber (WP Suspension), swingarm, linkage, steering head, wheel bearings, and frame inspection.
Brakes:
Front and rear brake system inspection, repair, bleeding, component replacement (calipers, master cylinders, lines, discs), and ABS system (if equipped).
Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), diagnostics, and adjustments.
Bodywork And Ergonomics:
Fairings, seat, fuel tank, fenders, handlebar, footpegs, and general cosmetic component removal and installation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable via diagnostic tools).
Major Repairs:
Engine rebuilds, gearbox overhauls, suspension component overhauls, brake system overhauls, and electrical system repairs.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, ensuring clarity of text, diagrams, and images. Searchable text for easy navigation.
Print Quality
Printability:
Designed for full or partial printing, allowing users to create physical copies of specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital PDF format).
Paper Type
Paper Type:
N/A (Digital PDF format).
Completeness
Content Scope:
Complete, encompassing all aspects of the 2010 KTM 690 Enduro R as designed and serviced by the factory.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled, DOHC
Displacement:
657.5 cc
Bore X Stroke:
102 mm x 80 mm
Compression Ratio:
12.3:1 (approx.)
Performance
Horsepower:
Approx. 63 hp @ 7,500 rpm (Factory spec may vary slightly)
Electronic Fuel Injection (EFI) with Keihin throttle body (typically 46mm)
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Lubrication
Oil Capacity With Filter Change:
Approx. 1.4 Liters (1.5 US qt)
Recommended Oil Grade:
SAE 10W-50 (or as per owner's manual, e.g., Motorex Power Synt 4T)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0)
🔧 Transmission
Standard
Type:
6-speed, claw-shifted
Clutch Type:
Wet multi-disc clutch, hydraulically operated
Features
Final Drive:
X-ring chain, 525 pitch
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 32/14, 2nd: 30/17, 3rd: 28/19, 4th: 25/21, 5th: 22/23, 6th: 24/27)
Transmission Oil Capacity:
Approx. 1.1 Liters (1.16 US qt)
Transmission Oil Grade:
SAE 75W (or as per manual, often similar to engine oil grades for shared sump systems, but confirmation is vital)
📐 Dimensions
Exterior
Length:
Approx. 2330 mm (91.7 in)
Width Without Mirrors:
Approx. 860 mm (33.9 in)
Height Seat:
Approx. 930 mm (36.6 in)
Ground Clearance:
Approx. 285 mm (11.2 in)
Weights
Dry Weight:
Approx. 146 kg (321.9 lbs)
Ready To Ride Weight Approx:
Approx. 160 kg (352.7 lbs) (with all fluids, without rider)
Gross Vehicle Weight Rating Gvwr:
Refer to chassis plate or manual (typically around 300-350 kg)
Wheels And Tires
Front Wheel Size:
21 x 1.85
Rear Wheel Size:
18 x 2.50
Front Tire Size:
90/90-21
Rear Tire Size:
140/80-18
Wheel Bolt Pattern:
N/A (Spoked wheels with bolt-on hub carriers)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles are generally not subjected to standardized crash testing like automobiles. Safety is primarily judged by design, equipment, and rider skill.
Active Features
Brakes:
Front: Single 300mm disc with 4-piston radial caliper; Rear: Single 240mm disc with 2-piston caliper. ABS available on some variants, consult manual for specifics.
Lighting:
Halogen headlight, LED taillight and indicators, ensuring visibility.
Handling:
Advanced suspension geometry and high-quality components contribute to stable and predictable handling.
Passive Features
Frame:
Strong steel trellis frame designed for rigidity and impact absorption.
Bodywork:
Durable plastics designed to withstand minor impacts and abrasions.
Ergonomics:
Handlebar design and control placement optimized for rider input and stability.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD display providing speed, RPM, odometer, trip meters, fuel level, gear indicator, and warning lights. The manual will cover its functions and troubleshooting.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an option or standard on certain markets for the 2010 model. The manual will detail its operation, disabling, and troubleshooting if equipped.
Connectivity
Diagnostics:
The manual will outline diagnostic procedures, potentially including information on accessing error codes through the instrument cluster or via an OBD-II interface if applicable for ECU readings.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first. Consult manual for precise intervals.
Air Filter Cleaning:
Recommended every 5,000-7,500 km (3,000-5,000 miles), or more frequently in dusty conditions.
Valve Clearance Check:
Typically at 10,000-15,000 km (6,000-9,000 miles) intervals. Crucial for maintaining performance and preventing damage.
Chain Maintenance:
Clean and lubricate every 500-1,000 km (300-600 miles) and adjust tension as needed. Check for wear.
Fluid Specifications
Engine Oil Grade:
SAE 10W-50, JASO MA/MA2 approved synthetic motorcycle oil (e.g., Motorex Power Synt 4T).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically pre-diluted 50/50 with distilled water (e.g., Motorex Coolant M3.0).
Brake Fluid Type:
DOT 4 (or as specified in manual), for both front and rear brake systems.
Clutch Fluid Type:
DOT 4 (or as specified in manual), for the hydraulic clutch system.
Known Issues
Fuel Pump Reliability:
Some early models or units with certain fuel types experienced occasional fuel pump issues. The manual will detail diagnostic and replacement procedures.
Engine Vibration:
As a large single-cylinder, the LC4 engine can produce noticeable vibrations. Proper engine mounting and balancer shaft operation are key, covered in the manual.
Suspension Seals:
Heavy off-road use can stress fork seals. Regular inspection and maintenance, detailed in the manual, are crucial.
Electrical Connections:
Ensuring clean and secure electrical connections is vital, especially given the vibration and exposure to elements. The manual's wiring diagrams are invaluable.
📚 Vehicle History
Brand Heritage
Ktm Legacy:
KTM has a strong heritage in off-road racing, particularly in motocross and enduro, which informs the design and engineering of their dual-sport and adventure models.
Model Evolution
Lc4 Lineage:
The 690 Enduro R builds upon KTM's long-standing 'LC4' single-cylinder engine platform, known for its robust nature and adaptability across various KTM models.
Enduro R Positioning:
The 'R' designation typically signifies a more performance-oriented or off-road focused version of the standard model, featuring enhanced suspension and other upgrades.
Production
Manufacturing Location:
Primarily Austria (Mattighofen), KTM's headquarters and primary manufacturing hub.
Model Run Years:
The 690 Enduro R has been produced in various iterations since its introduction, with significant updates over its lifespan.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2010 model year are hard to pinpoint without dedicated historical search, the 690 Enduro R generally receives praise from motorcycle publications for its off-road capability and powerful single-cylinder engine within the dual-sport category.