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KTM 690 Enduro R 2011 Factory Service Repair Manual

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The 2011 690 Enduro R is a versatile dual-sport motorcycle engineered for riders seeking robust performance both on and off the pavement. Building on a strong off-road racing heritage, this model features a lightweight, durable chassis, a powerful 654.7 cc single-cylinder engine, and long-travel WP suspension, making it exceptionally capable for adventure touring and challenging terrain. Its advanced electronics for the era, including switchable ABS, and a focus on build quality ensure reliability and a true 'Ready to Race' experience. This comprehensive Factory Service Repair Manual is designed to provide owners, mechanics, and technicians with the essential information needed to maintain, diagnose, and repair the 2011 690 Enduro R. Covering all major systems from the engine and fuel system to the electrical components and chassis, the manual includes detailed procedures for routine maintenance, component overhauls, and troubleshooting. With high-resolution diagrams, precise torque specifications, and step-by-step instructions, this English-language manual empowers users to keep their motorcycle in optimal condition and perform complex repairs with confidence. 🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2011 Chassis Code: KTM690E 2011 👋 Introduction Market Position Market Segment: Dual-sport / Adventure motorcycle, designed for both on-road and off-road riding capabilities. Competitive Analysis Key Competitors 2011: BMW G 650 GS Sertao, Kawasaki KLR650, Honda XR650L, Yamaha WR250R Key Features Usp Features: Lightweight chassis, powerful single-cylinder engine, long-travel suspension, robust build quality for off-road durability, advanced electronics for its class. Manual Value Proposition Value For Buyer: Provides essential information for owners to maintain, diagnose, and repair their KTM 690 Enduro R, saving time and money on dealership services. Empowers owners with factory-level technical knowledge. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Clutch, Transmission, Suspension, Brakes, Electrical System, Frame, Bodywork, Wheels, Tires, Troubleshooting, Maintenance Schedules Page Count Page Count: Hundreds of pages (exact count not specified, but described as comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, cylinder head, cylinder, piston, crankshaft, camshafts, valve timing, lubrication, oil pump, oil cooler, decompression mechanism Fuel System: Fuel pump, fuel injectors, throttle body, fuel pressure regulator, fuel filter, fuel tank, fuel level sensor Ignition System: Ignition coil, spark plug, ignition control unit (ECU), crankshaft position sensor, camshaft position sensor Cooling System: Radiator, fan, thermostat, water pump, coolant hoses, coolant specifications Clutch System: Clutch operation, clutch plates, clutch springs, clutch housing, clutch fluid (if applicable), clutch lever and cable adjustment Transmission System: Gearbox internal components, gear selection mechanism, transmission fluid type and capacity, shift drum, shift forks Suspension System: Front fork (WP Suspension), rear shock absorber (WP Suspension), fork oil type and level, suspension adjustments, seal replacement, damper servicing Brake System: Front and rear brake calipers (Brembo), brake discs, brake pads, brake fluid type and bleeding procedure, master cylinders, brake lines Electrical System: Wiring diagrams, battery specifications, starter motor, alternator, lighting system (headlight, taillight, turn signals), fuses, relays, instrument cluster functions, diagnostic connector Frame And Bodywork: Frame construction, subframe, body panels, seat, fuel tank mounting, fairings, fenders, graphics Wheels And Tires: Wheel specifications, spoke tension, tire pressure recommendations, rim types, bearing maintenance Procedures Included Maintenance Procedures: Oil and filter change, air filter cleaning/replacement, spark plug inspection/replacement, valve clearance adjustment, coolant flush and replacement, brake fluid replacement, chain adjustment and lubrication, tire pressure checks Repair Procedures: Engine disassembly and reassembly, transmission overhaul, clutch service, suspension fork service, brake caliper overhaul, starter motor replacement, electrical component diagnosis and repair Troubleshooting Guides: Diagnostic charts for common problems, fault codes and their meanings, step-by-step troubleshooting steps for various systems Electrical Troubleshooting: Includes detailed wiring diagrams, component testing procedures, and troubleshooting trees for electrical system faults. Suspension Tuning And Servicing: Covers fork oil changes, seal replacement, internal valving inspection, and rear shock absorber servicing, along with adjustment procedures for preload, compression, and rebound damping. Technical Depth Depth Of Coverage: Comprehensive coverage from basic maintenance and adjustments to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications. Torque Specifications: Provides precise torque values for all critical fasteners, ensuring proper assembly and preventing damage. Special Tools: Lists required special tools for specific maintenance and repair procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Allows for clear reproduction of diagrams and text. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, SOHC, 4 valves with roller rocker arms Engine Displacement: 654.7 cc Bore X Stroke: 102 mm x 80 mm Compression Ratio: 12.3:1 Engine Cooling: Liquid-cooled Valve Actuation: Single Overhead Camshaft (SOHC) with roller rocker arms for reduced friction and improved durability. Performance Peak Horsepower: Approximately 63 hp (46.3 kW)...
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Tipo: Motorcycle
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Sku: 78573
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KTM 690 Enduro R 2011 Factory Service Repair ManualKTM 690 Enduro R 2011 Factory Service Repair ManualKTM 690 Enduro R 2011 Factory Service Repair ManualKTM 690 Enduro R 2011 Factory Service Repair Manual
The 2011 690 Enduro R is a versatile dual-sport motorcycle engineered for riders seeking robust performance both on and off the pavement. Building on a strong off-road racing heritage, this model features a lightweight, durable chassis, a powerful 654.7 cc single-cylinder engine, and long-travel WP suspension, making it exceptionally capable for adventure touring and challenging terrain. Its advanced electronics for the era, including switchable ABS, and a focus on build quality ensure reliability and a true 'Ready to Race' experience. This comprehensive Factory Service Repair Manual is designed to provide owners, mechanics, and technicians with the essential information needed to maintain, diagnose, and repair the 2011 690 Enduro R. Covering all major systems from the engine and fuel system to the electrical components and chassis, the manual includes detailed procedures for routine maintenance, component overhauls, and troubleshooting. With high-resolution diagrams, precise torque specifications, and step-by-step instructions, this English-language manual empowers users to keep their motorcycle in optimal condition and perform complex repairs with confidence.
🏷️ Basic Information
Identification
Make:
KTM
Model:
690 Enduro R
Year:
2011
Chassis Code:
KTM690E 2011
👋 Introduction
Market Position
Market Segment:
Dual-sport / Adventure motorcycle, designed for both on-road and off-road riding capabilities.
Competitive Analysis
Key Competitors 2011:
BMW G 650 GS Sertao, Kawasaki KLR650, Honda XR650L, Yamaha WR250R
Key Features
Usp Features:
Lightweight chassis, powerful single-cylinder engine, long-travel suspension, robust build quality for off-road durability, advanced electronics for its class.
Manual Value Proposition
Value For Buyer:
Provides essential information for owners to maintain, diagnose, and repair their KTM 690 Enduro R, saving time and money on dealership services. Empowers owners with factory-level technical knowledge.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Clutch, Transmission, Suspension, Brakes, Electrical System, Frame, Bodywork, Wheels, Tires, Troubleshooting, Maintenance Schedules
Page Count
Page Count:
Hundreds of pages (exact count not specified, but described as comprehensive)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, cylinder head, cylinder, piston, crankshaft, camshafts, valve timing, lubrication, oil pump, oil cooler, decompression mechanism
Fuel System:
Fuel pump, fuel injectors, throttle body, fuel pressure regulator, fuel filter, fuel tank, fuel level sensor
Ignition System:
Ignition coil, spark plug, ignition control unit (ECU), crankshaft position sensor, camshaft position sensor
Cooling System:
Radiator, fan, thermostat, water pump, coolant hoses, coolant specifications
Clutch System:
Clutch operation, clutch plates, clutch springs, clutch housing, clutch fluid (if applicable), clutch lever and cable adjustment
Transmission System:
Gearbox internal components, gear selection mechanism, transmission fluid type and capacity, shift drum, shift forks
Suspension System:
Front fork (WP Suspension), rear shock absorber (WP Suspension), fork oil type and level, suspension adjustments, seal replacement, damper servicing
Brake System:
Front and rear brake calipers (Brembo), brake discs, brake pads, brake fluid type and bleeding procedure, master cylinders, brake lines
Electrical System:
Wiring diagrams, battery specifications, starter motor, alternator, lighting system (headlight, taillight, turn signals), fuses, relays, instrument cluster functions, diagnostic connector
Frame And Bodywork:
Frame construction, subframe, body panels, seat, fuel tank mounting, fairings, fenders, graphics
Wheels And Tires:
Wheel specifications, spoke tension, tire pressure recommendations, rim types, bearing maintenance
Procedures Included
Maintenance Procedures:
Oil and filter change, air filter cleaning/replacement, spark plug inspection/replacement, valve clearance adjustment, coolant flush and replacement, brake fluid replacement, chain adjustment and lubrication, tire pressure checks
Repair Procedures:
Engine disassembly and reassembly, transmission overhaul, clutch service, suspension fork service, brake caliper overhaul, starter motor replacement, electrical component diagnosis and repair
Troubleshooting Guides:
Diagnostic charts for common problems, fault codes and their meanings, step-by-step troubleshooting steps for various systems
Electrical Troubleshooting:
Includes detailed wiring diagrams, component testing procedures, and troubleshooting trees for electrical system faults.
Suspension Tuning And Servicing:
Covers fork oil changes, seal replacement, internal valving inspection, and rear shock absorber servicing, along with adjustment procedures for preload, compression, and rebound damping.
Technical Depth
Depth Of Coverage:
Comprehensive coverage from basic maintenance and adjustments to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
Torque Specifications:
Provides precise torque values for all critical fasteners, ensuring proper assembly and preventing damage.
Special Tools:
Lists required special tools for specific maintenance and repair procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual. Allows for clear reproduction of diagrams and text.
Binding Type
Binding Type:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, SOHC, 4 valves with roller rocker arms
Engine Displacement:
654.7 cc
Bore X Stroke:
102 mm x 80 mm
Compression Ratio:
12.3:1
Engine Cooling:
Liquid-cooled
Valve Actuation:
Single Overhead Camshaft (SOHC) with roller rocker arms for reduced friction and improved durability.
Performance
Peak Horsepower:
Approximately 63 hp (46.3 kW) @ 7,750 rpm (subject to market and tuning)
Peak Torque:
Approximately 6.3 kgm (61.8 Nm; 45.6 lb-ft) @ 6,000 rpm (subject to market and tuning)
Fuel System
Fuel Delivery:
Electronic fuel injection (EFI) with Keihin EMS
Fuel Type:
Unleaded gasoline, minimum 95 RON (octane rating)
Lubrication
Oil Type:
Motorex Power Synt 4T 10W/50 or similar API SJ, JASO MA certified synthetic oil
Oil Capacity:
Approx. 1.7 liters (1.8 US qt) without filter change; Approx. 1.9 liters (2.0 US qt) with filter change
🔧 Transmission
Standard
Transmission Type:
6-speed, claw shifted
Gear Ratios:
1st: 2.5:1, 2nd: 1.77:1, 3rd: 1.38:1, 4th: 1.15:1, 5th: 1.04:1, 6th: 0.96:1 (Gearbox ratios may vary slightly)
Optional
Optional Gear Ratios:
N/A (Single gear ratio set as standard)
Features
Clutch Type:
APTCC (Anti-hopping, pressure-assisted, cable-actuated) wet multi-disc clutch
Final Drive:
Chain drive, O-ring sealed, 520 pitch
📐 Dimensions
Exterior
Length Overall:
Approx. 2,300 mm (90.6 in)
Width Overall:
Approx. 900 mm (35.4 in)
Seat Height Unladen:
Approx. 910 mm (35.8 in)
Ground Clearance:
Approx. 285 mm (11.2 in)
Wheelbase:
Approx. 1,500 mm ± 10 mm (59.1 in ± 0.4 in)
Seat Height Laden:
Varies with rider weight and suspension sag.
Weights
Dry Weight:
Approx. 144 kg (317.5 lbs)
Fuel Tank Capacity:
Approx. 12 liters (3.17 US gal), of which approx. 2.5 liters (0.66 US gal) are reserve
Gross Vehicle Weight Rating:
Not explicitly stated, but typically exceeds dry weight by rider and cargo capacity. Manual would detail maximum load.
🛡️ Safety Features
Ratings
Safety Certification:
CE, EPA (depending on market)
Active Features
Braking System:
Advanced Brembo braking system with ABS (switchable), designed for optimal control in diverse conditions.
Passive Features
Frame Construction:
Lightweight yet strong chrome-molybdenum steel trellis frame providing torsional rigidity and impact absorption.
Lighting:
Integrated LED taillight and bright halogen headlight for enhanced visibility.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD display featuring speedometer, tachometer, odometer, trip meter, fuel level indicator, gear indicator, clock, and various warning lights.
Driver Assistance
ABS System:
Switchable ABS (Anti-lock Braking System) for enhanced safety, allowing deactivation for off-road use.
Connectivity
Diagnostic Interface:
On-board diagnostics (OBD) port for connecting diagnostic tools to read fault codes and monitor engine parameters.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 7,500 km (4,660 miles) or 12 months, whichever comes first.
Air Filter Check Clean:
Every 3,750 km (2,330 miles) or more frequently in dusty conditions.
Spark Plug Inspection:
Every 7,500 km (4,660 miles).
Valve Clearance Check:
Every 7,500 km (4,660 miles).
Chain Maintenance:
Clean and lubricate chain every 1,000 km (620 miles) or more frequently in adverse conditions. Check and adjust chain tension every 1,000 km (620 miles).
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Type:
KTM Coolant (ready-mix) or equivalent mixture of distilled water and anti-freeze (e.g., ethylene glycol based, with corrosion inhibitors), typically 50/50 ratio.
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets due to high-performance use.
Potential Refinements 2011:
Some early models might have benefited from software updates for fuel mapping or minor tweaks to suspension settings. The manual would detail any factory service bulletins.
Electrical Connections:
Ensure all electrical connectors are clean and secure, especially those exposed to moisture, to prevent intermittent faults.
📚 Vehicle History
Brand Heritage
Ktm Offroad Legacy:
KTM has a rich heritage in off-road racing, particularly in motocross and enduro, building a reputation for performance, durability, and 'Ready to Race' philosophy.
Model Evolution
690 Enduro R Development:
The 690 Enduro R represents KTM's evolution of the versatile dual-sport platform, building on previous LC4 engine designs and focusing on a more powerful, refined, and capable package for adventure riding.
Production
Manufacturing Location:
Austria (KTM Sportmotorcycle AG)
🏆 Awards & Recognition
Recognitions
Industry Recognition:
While specific awards for the 2011 model year are not readily cataloged, KTM motorcycles consistently receive positive reviews and accolades in the adventure and dual-sport segments for their performance and off-road prowess.
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