KTM 690 Enduro R 2009 Workshop Repair Service Manual
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๐ท๏ธ 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) ๐ 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). ๐ 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 ๐ 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. ๐ 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) โ๏ธ 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. ๐ง 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). ๐ 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. ๐ก๏ธ 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. ๐ก 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). ๐ง 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...
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.
๐ 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)
โ๏ธ 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).
๐ 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.
๐ก๏ธ 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.
๐ก 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).
๐ง 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.
๐ 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).
๐ 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.