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KTM 690 Enduro R 2012 Service Repair Workshop Manual

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The 690 Enduro R is a versatile dual-sport motorcycle renowned for its potent LC4 single-cylinder engine and agile handling, designed for riders who demand off-road capability without compromising street legality. Built on a strong off-road racing heritage, this 2012 model embodies a lightweight, agile design philosophy, offering impressive performance on challenging terrain while maintaining manageable street manners. Its robust trellis frame and powerful, liquid-cooled engine make it a formidable machine for adventure touring and spirited riding. This comprehensive workshop manual provides full service and repair information for the 2012 690 Enduro R. It covers all major systems, including the engine, transmission, chassis, electrical system, fuel system, and braking system, detailing routine maintenance, troubleshooting, diagnostics, and complete repair procedures. With precise specifications, torque values, and clear instructions, this manual is an essential resource for owners and professional technicians seeking to maintain, repair, and optimize the performance and longevity of their motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2012 Codes Engine Code: LC4 (Single Cylinder, Four-Stroke) 👋 Introduction Market Position Category: Dual-sport / Adventure Motorcycle Target Audience: Riders seeking off-road capability with street legality Competitive Analysis Competitors: BMW G 650GS Sertao, Kawasaki KLR650, Yamaha WR250R Key Features Design Philosophy: Lightweight, agile, off-road focused with manageable street manners Platform: Built on the renowned KTM LC4 engine platform 📋 Manual Details Coverage Areas Scope: Full service and repair Page Count Estimated Pages: Approximately 300-500 (typical for comprehensive workshop manuals) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system Transmission: Gearbox, clutch, shifting mechanisms, lubrication Chassis: Frame, swingarm, suspension (front and rear), steering system Electrical System: Ignition system, lighting, starter system, battery, wiring diagrams, sensors, ECUs Fuel System: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, lines Braking System: Hydraulic brake system (master cylinders, calipers, discs, lines), bleeding procedures Exhaust System: Exhaust manifold, catalytic converter, muffler, lambda sensors Wheels And Tires: Wheel removal and installation, tire pressure, rim specifications Bodywork: Fairings, seat, fuel tank cover, fenders, panel removal and installation Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, valve clearance checks Troubleshooting: Diagnostic procedures, common fault identification and rectification Repair: Component disassembly, repair, and reassembly for all major systems Diagnostics: Fault codes, sensor testing, electrical system diagnostics Specifications: Torque values, clearances, fluid capacities, electrical resistance values Technical Depth Depth: Comprehensive; suitable for professional mechanics and experienced DIY enthusiasts 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (typically for official PDFs) Print Quality Printability: Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled (LC4) Displacement: 650cc (approx. 690cc for later revisions, confirmation needed for specific 2012 model) Bore X Stroke: 102 mm x 84 mm (typical for this engine family) Compression Ratio: 12.6:1 (typical) Valve Train: SOHC, 4 valves per cylinder Lubrication: Wet sump with integrated oil cooler Performance Horsepower: Approximately 60-65 HP (at crank), depending on market and tune Torque: Approximately 50-55 lb-ft (at crank) Fuel System Fuel Delivery: Electronic fuel injection (EFI) with Keihin throttle body Fuel Type: Unleaded gasoline, minimum 95 RON Ignition Ignition System: Digital CDI with ignition timing adjustment Starting System Starter: Electric starter 🔧 Transmission Standard Transmission Type: 6-speed, claw-shifted Clutch: Wet multi-disc clutch, hydraulically actuated Features Gear Ratios: Specific ratios detailed in manual (e.g., 1st: 2.15, 2nd: 1.62, 3rd: 1.29, 4th: 1.05, 5th: 0.92, 6th: 0.79) Final Drive: Chain drive, 16/45T sprockets (typical, confirm for 2012) 📐 Dimensions Exterior Length: Approximately 2300 mm (2012 model) Width: Approximately 915 mm (2012 model) Height: Approximately 1420 mm (2012 model, without mirrors) Wheelbase: Approximately 1500 mm (2012 model) Weights Dry Weight: Approximately 140 kg (2012 model) Wet Weight: Approximately 150 kg (with fluids, 2012 model) Max Payload: Approximately 180 kg (rider and luggage) Cargo Luggage Capacity: Minimal integrated; accessory luggage systems available 🛡️ Safety Features Ratings Safety Certification: DOT, ECE (depending on market regulations) Active Features Brakes: Disc brakes front and rear with optional ABS (may be market specific) Lighting: Halogen headlight, LED taillight and turn signals Passive Features Chassis Design: Robust trellis frame for rigidity and impact resistance Handguards: Standard integrated handguards for rider protection 💡 Technology Features Infotainment Display: LCD multi-function instrument cluster (speedometer, tachometer, gear indicator, odometer, trip meters, clock) Driver Assistance ABS: Optional Anti-lock Braking System (ABS) - refer to manual for activation/deactivation procedures if applicable Connectivity Connectivity Features: None (typical for this era of performance dual-sport) 🔧 Maintenance Service Intervals Oil Change: Every 5,000 - 10,000 km or annually (refer to manual for exact interval) Valve Clearance: Every 10,000 km or annually (typical for LC4 engines) Chain Maintenance: Lubricate and adjust every 500-800 km...
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KTM 690 Enduro R 2012 Service Repair Workshop ManualKTM 690 Enduro R 2012 Service Repair Workshop ManualKTM 690 Enduro R 2012 Service Repair Workshop Manual
The 690 Enduro R is a versatile dual-sport motorcycle renowned for its potent LC4 single-cylinder engine and agile handling, designed for riders who demand off-road capability without compromising street legality. Built on a strong off-road racing heritage, this 2012 model embodies a lightweight, agile design philosophy, offering impressive performance on challenging terrain while maintaining manageable street manners. Its robust trellis frame and powerful, liquid-cooled engine make it a formidable machine for adventure touring and spirited riding. This comprehensive workshop manual provides full service and repair information for the 2012 690 Enduro R. It covers all major systems, including the engine, transmission, chassis, electrical system, fuel system, and braking system, detailing routine maintenance, troubleshooting, diagnostics, and complete repair procedures. With precise specifications, torque values, and clear instructions, this manual is an essential resource for owners and professional technicians seeking to maintain, repair, and optimize the performance and longevity of their motorcycle.
🏷️ Basic Information
Identification
Make:
KTM
Model:
690 Enduro R
Year:
2012
Codes
Engine Code:
LC4 (Single Cylinder, Four-Stroke)
👋 Introduction
Market Position
Category:
Dual-sport / Adventure Motorcycle
Target Audience:
Riders seeking off-road capability with street legality
Competitive Analysis
Competitors:
BMW G 650GS Sertao, Kawasaki KLR650, Yamaha WR250R
Key Features
Design Philosophy:
Lightweight, agile, off-road focused with manageable street manners
Platform:
Built on the renowned KTM LC4 engine platform
📋 Manual Details
Coverage Areas
Scope:
Full service and repair
Page Count
Estimated Pages:
Approximately 300-500 (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system
Transmission:
Gearbox, clutch, shifting mechanisms, lubrication
Chassis:
Frame, swingarm, suspension (front and rear), steering system
Electrical System:
Ignition system, lighting, starter system, battery, wiring diagrams, sensors, ECUs
Fuel System:
Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, lines
Braking System:
Hydraulic brake system (master cylinders, calipers, discs, lines), bleeding procedures
Exhaust System:
Exhaust manifold, catalytic converter, muffler, lambda sensors
Wheels And Tires:
Wheel removal and installation, tire pressure, rim specifications
Bodywork:
Fairings, seat, fuel tank cover, fenders, panel removal and installation
Procedures Included
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, valve clearance checks
Troubleshooting:
Diagnostic procedures, common fault identification and rectification
Repair:
Component disassembly, repair, and reassembly for all major systems
Diagnostics:
Fault codes, sensor testing, electrical system diagnostics
Specifications:
Torque values, clearances, fluid capacities, electrical resistance values
Technical Depth
Depth:
Comprehensive; suitable for professional mechanics and experienced DIY enthusiasts
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (typically for official PDFs)
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled (LC4)
Displacement:
650cc (approx. 690cc for later revisions, confirmation needed for specific 2012 model)
Bore X Stroke:
102 mm x 84 mm (typical for this engine family)
Compression Ratio:
12.6:1 (typical)
Valve Train:
SOHC, 4 valves per cylinder
Lubrication:
Wet sump with integrated oil cooler
Performance
Horsepower:
Approximately 60-65 HP (at crank), depending on market and tune
Torque:
Approximately 50-55 lb-ft (at crank)
Fuel System
Fuel Delivery:
Electronic fuel injection (EFI) with Keihin throttle body
Fuel Type:
Unleaded gasoline, minimum 95 RON
Ignition
Ignition System:
Digital CDI with ignition timing adjustment
Starting System
Starter:
Electric starter
🔧 Transmission
Standard
Transmission Type:
6-speed, claw-shifted
Clutch:
Wet multi-disc clutch, hydraulically actuated
Features
Gear Ratios:
Specific ratios detailed in manual (e.g., 1st: 2.15, 2nd: 1.62, 3rd: 1.29, 4th: 1.05, 5th: 0.92, 6th: 0.79)
Final Drive:
Chain drive, 16/45T sprockets (typical, confirm for 2012)
📐 Dimensions
Exterior
Length:
Approximately 2300 mm (2012 model)
Width:
Approximately 915 mm (2012 model)
Height:
Approximately 1420 mm (2012 model, without mirrors)
Wheelbase:
Approximately 1500 mm (2012 model)
Weights
Dry Weight:
Approximately 140 kg (2012 model)
Wet Weight:
Approximately 150 kg (with fluids, 2012 model)
Max Payload:
Approximately 180 kg (rider and luggage)
Cargo
Luggage Capacity:
Minimal integrated; accessory luggage systems available
🛡️ Safety Features
Ratings
Safety Certification:
DOT, ECE (depending on market regulations)
Active Features
Brakes:
Disc brakes front and rear with optional ABS (may be market specific)
Lighting:
Halogen headlight, LED taillight and turn signals
Passive Features
Chassis Design:
Robust trellis frame for rigidity and impact resistance
Handguards:
Standard integrated handguards for rider protection
💡 Technology Features
Infotainment
Display:
LCD multi-function instrument cluster (speedometer, tachometer, gear indicator, odometer, trip meters, clock)
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) - refer to manual for activation/deactivation procedures if applicable
Connectivity
Connectivity Features:
None (typical for this era of performance dual-sport)
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 10,000 km or annually (refer to manual for exact interval)
Valve Clearance:
Every 10,000 km or annually (typical for LC4 engines)
Chain Maintenance:
Lubricate and adjust every 500-800 km or as needed
Air Filter:
Clean/replace every 5,000 km or as needed, especially in dusty conditions
Fluid Specifications
Engine Oil:
SAE 10W-50, JASO MA approved (e.g., Motorex Power Synt 4T 10W-50)
Coolant:
Mixture of distilled water and antifreeze (e.g., Engine Ice, or a 50/50 mix of ethylene glycol and distilled water)
Brake Fluid:
DOT 4
Clutch Fluid:
DOT 4
Fork Oil:
SAE 5W (specific type and volume detailed in manual)
Known Issues
Fuel Pump Reliability:
Early models sometimes experienced fuel pump failures; manual will detail checks and replacement
Vibration:
Single-cylinder engines can produce vibrations; counterbalancers are employed, but some resonance can be felt
Cam Chain Tensioner:
Can require periodic inspection/replacement as part of routine maintenance
📚 Vehicle History
Brand Heritage
Brand Focus:
KTM is renowned for its off-road racing heritage and 'Ready to Race' philosophy
Model Evolution
Lc4 Legacy:
The 690 Enduro R builds upon the long-standing and highly regarded LC4 engine platform, known for its torque and durability
Generation:
The 2012 model represents a key iteration of the 690 Enduro R, incorporating refinements from earlier models
Production
Manufacturing Location:
Austria (KTM AG)
🏆 Awards & Recognition
Recognitions
Industry Reputation:
KTM 690 Enduro R is widely respected for its off-road prowess and versatility in its class
Ratings
Motorcycle Reviews:
Consistently praised by motorcycle publications for its performance and handling both on and off-road
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