KTM 690 Enduro R 2012 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2012 Codes Vin Prefix: VBK 👋 Introduction Market Position Segment: Lightweight Adventure/Dual-Sport Motorcycle Competitive Analysis Competitors: BMW G 650 GS Sertao, Husqvarna 701 Enduro (later models), Honda CRF250L/CRF450L (though less powerful/capable), Yamaha WR250R Key Features Features: Powerful single-cylinder engine, advanced WP suspension, lightweight chassis, off-road capability, ABS (switchable on later models), user-friendly EFI. 📋 Manual Details Coverage Areas Models Covered: All 690 Enduro R models, all engines, all trims, all transmissions Page Count Estimated Pages: 300+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (LC4, single-cylinder, 4-stroke), Fuel System (EFI, KTM's 'Dual Spark' ignition), Exhaust System, Lubrication System Chassis: Frame, Swingarm, Suspension (WP Suspension - Forks and Monoshock), Brakes (Brembo - Front and Rear), Wheels, Tires, Steering Electrical: Ignition System, Lighting System, Battery, Charging System, Starter Motor, Wiring Harness, ECU, Instrument Cluster Bodywork: Fairings, Seat, Fuel Tank, Fenders, Handlebars, Controls Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, chain adjustment, valve clearance checks), Pre-ride inspections Repair: Engine rebuilds, transmission servicing, suspension overhaul, brake system repairs, electrical component replacement, bodywork repairs Troubleshooting: Diagnostic procedures for common faults, electrical system diagnostics, engine performance issues Technical Depth Depth: Comprehensive: Covers basic maintenance to full engine and chassis overhauls, including detailed torque specifications and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: Digital PDF Print Quality Quality: High-resolution, printable pages with clear diagrams and text. Binding Type Binding: Not Applicable (PDF Download) Paper Type Paper: Not Applicable (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: LC4, Single-cylinder, 4-stroke Displacement: 657.5 cc Bore X Stroke: 102 mm x 80 mm Compression Ratio: 12.3:1 Performance Horsepower: Approx. 63 hp (47 kW) @ 7,500 rpm Torque: Approx. 50 lb-ft (68 Nm) @ 6,000 rpm Fuel System Fuel Delivery: Fuel Injection (Keihin EFI) Ignition System: Dual Spark Ignition System Cooling System Cooling Method: Liquid Cooled Lubrication Oil Type: SAE 10W-50 Synthetic Motorcycle Oil Oil Capacity: Approx. 1.7 liters (1.8 US qt) without filter change, 1.9 liters (2.0 US qt) with filter change 🔧 Transmission Standard Transmission Type: 6-Speed Sequential Manual Optional Optional Transmissions: N/A Features Clutch: Wet Multi-disc Clutch, Hydraulically Operated Gear Ratios Gear Ratios: Refer to manual for specific ratios (typically optimized for off-road and street use) Final Drive Final Drive Type: X-Ring Chain 📐 Dimensions Exterior Length: Approx. 2300 mm (90.6 in) Width: Approx. 915 mm (36.0 in) Height: Approx. 1420 mm (55.9 in) (to windshield/fairing) Seat Height: Approx. 910 mm (35.8 in) Wheelbase: Approx. 1500 mm (59.1 in) Weights Dry Weight: Approx. 144 kg (317.5 lbs) Wet Weight: Approx. 160 kg (352.7 lbs) Cargo Cargo Capacity: N/A (Designed for rider and minimal luggage, mounting points for luggage racks available) Fuel Capacity Fuel Tank Capacity: Approx. 12 liters (3.17 US gal) 🛡️ Safety Features Ratings Safety Ratings: Not applicable in the same way as automobiles; designed for off-road durability and rider control. Active Features Braking System: Hydraulic Disc Brakes (Brembo), ABS (optional/switchable on some models) Traction Control: Not standard on 2012 model Passive Features Lighting: Halogen Headlight, LED Taillight Instrumentation: Digital LCD display with tachometer, speedometer, odometer, trip meters, fuel level, gear indicator. 💡 Technology Features Infotainment Infotainment System: Not applicable; focus is on functionality and off-road performance. Driver Assistance ABS: Optional/Switchable Anti-lock Braking System available on certain variants. Connectivity Connectivity Features: None (designed for off-road, not street connectivity focus). Engine Management ECU: Engine Control Unit (ECU) for fuel injection and ignition timing management. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,100 miles) or annually. Air Filter Cleaning: Every 5,000 km (3,100 miles) or as needed based on conditions. Valve Clearance Check: Every 10,000 km (6,200 miles). Spark Plug Replacement: Refer to manual for specific interval, typically around 10,000-15,000 km. Fluid Specifications Coolant: Mixture of distilled water and antifreeze (e.g., Motorex Coolant M3.0), at least 40% antifreeze. Brake Fluid: DOT 4 Hydraulic Brake Fluid Fork Oil: WP Suspension Fork Oil (e.g., WP Suspension Fluid 5 WT) - Specific viscosity and quantity detailed in manual. Known Issues Common Problems: Potential for fuel pump issues (especially with ethanol fuels), clutch slave cylinder leaks, occasional electrical connector corrosion, vibration characteristics typical of large singles. Common Issues Solutions: Manual provides diagnostic steps for these issues and OEM/aftermarket part recommendations for repairs. Brake Pads Front Brake Pad Part Number: Refer to manual for specific KTM part numbers (e.g., 54805001000 or equivalent). Rear Brake Pad Part Number: Refer to manual for specific KTM part numbers (e.g., 54805000400 or equivalent). Filters Oil Filter Part Number: Refer to manual for specific KTM part numbers (e.g., 75038005000 or equivalent). Air Filter Part Number: Refer to manual for specific KTM part numbers (e.g., 76508005000 or equivalent). 📚 Vehicle History Brand Heritage Heritage: KTM, known as 'Ready...
Diagnostic procedures for common faults, electrical system diagnostics, engine performance issues
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to full engine and chassis overhauls, including detailed torque specifications and diagnostic flowcharts.
📊 Manual Specifications
File Format
File Type:
Digital PDF
Print Quality
Quality:
High-resolution, printable pages with clear diagrams and text.
Binding Type
Binding:
Not Applicable (PDF Download)
Paper Type
Paper:
Not Applicable (PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
LC4, Single-cylinder, 4-stroke
Displacement:
657.5 cc
Bore X Stroke:
102 mm x 80 mm
Compression Ratio:
12.3:1
Performance
Horsepower:
Approx. 63 hp (47 kW) @ 7,500 rpm
Torque:
Approx. 50 lb-ft (68 Nm) @ 6,000 rpm
Fuel System
Fuel Delivery:
Fuel Injection (Keihin EFI)
Ignition System:
Dual Spark Ignition System
Cooling System
Cooling Method:
Liquid Cooled
Lubrication
Oil Type:
SAE 10W-50 Synthetic Motorcycle Oil
Oil Capacity:
Approx. 1.7 liters (1.8 US qt) without filter change, 1.9 liters (2.0 US qt) with filter change
🔧 Transmission
Standard
Transmission Type:
6-Speed Sequential Manual
Optional
Optional Transmissions:
N/A
Features
Clutch:
Wet Multi-disc Clutch, Hydraulically Operated
Gear Ratios
Gear Ratios:
Refer to manual for specific ratios (typically optimized for off-road and street use)
Final Drive
Final Drive Type:
X-Ring Chain
📐 Dimensions
Exterior
Length:
Approx. 2300 mm (90.6 in)
Width:
Approx. 915 mm (36.0 in)
Height:
Approx. 1420 mm (55.9 in) (to windshield/fairing)
Seat Height:
Approx. 910 mm (35.8 in)
Wheelbase:
Approx. 1500 mm (59.1 in)
Weights
Dry Weight:
Approx. 144 kg (317.5 lbs)
Wet Weight:
Approx. 160 kg (352.7 lbs)
Cargo
Cargo Capacity:
N/A (Designed for rider and minimal luggage, mounting points for luggage racks available)
Fuel Capacity
Fuel Tank Capacity:
Approx. 12 liters (3.17 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable in the same way as automobiles; designed for off-road durability and rider control.
Active Features
Braking System:
Hydraulic Disc Brakes (Brembo), ABS (optional/switchable on some models)
Traction Control:
Not standard on 2012 model
Passive Features
Lighting:
Halogen Headlight, LED Taillight
Instrumentation:
Digital LCD display with tachometer, speedometer, odometer, trip meters, fuel level, gear indicator.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable; focus is on functionality and off-road performance.
Driver Assistance
ABS:
Optional/Switchable Anti-lock Braking System available on certain variants.
Connectivity
Connectivity Features:
None (designed for off-road, not street connectivity focus).
Engine Management
ECU:
Engine Control Unit (ECU) for fuel injection and ignition timing management.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,100 miles) or annually.
Air Filter Cleaning:
Every 5,000 km (3,100 miles) or as needed based on conditions.
Valve Clearance Check:
Every 10,000 km (6,200 miles).
Spark Plug Replacement:
Refer to manual for specific interval, typically around 10,000-15,000 km.
Fluid Specifications
Coolant:
Mixture of distilled water and antifreeze (e.g., Motorex Coolant M3.0), at least 40% antifreeze.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Fork Oil:
WP Suspension Fork Oil (e.g., WP Suspension Fluid 5 WT) - Specific viscosity and quantity detailed in manual.
Known Issues
Common Problems:
Potential for fuel pump issues (especially with ethanol fuels), clutch slave cylinder leaks, occasional electrical connector corrosion, vibration characteristics typical of large singles.
Common Issues
Solutions:
Manual provides diagnostic steps for these issues and OEM/aftermarket part recommendations for repairs.
Brake Pads
Front Brake Pad Part Number:
Refer to manual for specific KTM part numbers (e.g., 54805001000 or equivalent).
Rear Brake Pad Part Number:
Refer to manual for specific KTM part numbers (e.g., 54805000400 or equivalent).
Filters
Oil Filter Part Number:
Refer to manual for specific KTM part numbers (e.g., 75038005000 or equivalent).
Air Filter Part Number:
Refer to manual for specific KTM part numbers (e.g., 76508005000 or equivalent).
📚 Vehicle History
Brand Heritage
Heritage:
KTM, known as 'Ready to Race', has a strong heritage in off-road racing, particularly motocross and enduro.
Model Evolution
Evolution Of 690:
The 690 platform has evolved significantly, starting with the Duke and Adventure variants. The Enduro R version specifically targets a more aggressive off-road-biased dual-sport riding experience, building on the core LC4 engine and chassis.
Production
Production Location:
Austria (KTM AG)
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2012 model might be scarce, the 690 Enduro platform is widely recognized for its class-leading performance and off-road prowess within the dual-sport community.
Ratings
User Ratings:
Consistently high user ratings for performance, suspension, and handling in off-road conditions.
Certifications
Emissions Certification:
Meets relevant emissions standards for its model year (e.g., Euro 3).