KTM 690 Enduro R 2010 Service Repair Manual

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Stichworte: 2010 690 Enduro R KTM Misc Motorcycle Motorcycles

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Beschreibung

The 690 Enduro R, a 2010 model, represents a potent dual-sport and adventure motorcycle celebrated for its lightweight design and powerful single-cylinder LC4 engine. Engineered with a focus on off-road prowess, this street-legal machine is equally adept at adventure touring, offering a unique blend of performance and versatility. Its robust construction, stemming from a strong off-road and racing heritage, ensures reliability and capability in demanding conditions. This comprehensive Service and Repair Manual provides complete coverage for the 690 Enduro R. It details essential maintenance procedures, including routine servicing, engine rebuilds, suspension adjustments, and brake system repairs. The manual also covers troubleshooting, electrical diagnostics, and technical specifications, such as torque values and clearances. With detailed illustrations and step-by-step instructions, this English-language manual is an invaluable resource for owners and technicians seeking to maintain, repair, and optimize their vehicle.

🏷️ Basic Information

Identification

Make:

Model:

690 Enduro R

Year:

Product Type:

Service Repair Manual

Format:

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure motorcycle

Target Audience:

Owners and independent workshops focused on off-road riding and adventure touring.

Competitive Analysis

Competitors:

Yamaha WR250R, BMW G 450 X, Husqvarna TE series.

Key Features Vehicle

Lightweight, potent single-cylinder engine with a focus on off-road capability while still being street-legal and suitable for adventure touring.

Key Features Manual

Value Proposition:

Provides essential information for maintaining, troubleshooting, and repairing the KTM 690 Enduro R, enabling owners to perform tasks that might otherwise require dealership service.

📋 Manual Details

Coverage Areas

Coverage:

Complete service and repair coverage

Page Count

Estimated Pages:

300-400

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Digital Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed breakdown, assembly, inspection, and repair of all engine components (cylinder head, piston, crankshaft, camshaft, valves, timing).

Fuel System:

Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, fuel lines.

Ignition System:

Ignition coil, spark plug, ECU control, timing.

Cooling System:

Radiator, fan, thermostat, coolant circulation, bleeding procedures.

Exhaust System:

Muffler, catalytic converter, exhaust manifold, lambda sensor (O2 sensor).

Transmission Drivetrain:

Clutch operation, gearbox internals, shift mechanism, final drive (chain and sprockets).

Suspension Front:

Fork internals, seals, oil type and level, spring replacement, adjustment procedures.

Suspension Rear:

Shock absorber, linkage, bearings, adjustment and rebuild procedures.

Brakes Front:

Brake caliper, master cylinder, brake disc, pads, hydraulic lines, bleeding.

Brakes Rear:

Brake caliper, master cylinder, brake disc, pads, hydraulic lines, bleeding.

Wheel Assembly:

Wheel bearings, spoke tension, tire mounting and balancing.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, horn, indicators.

Instrumentation:

Dashboard, sensors (speed, RPM, temperature), warning lights.

Frame Chassis:

Frame inspection, subframe, steering head bearings.

Bodywork:

Fairings, fuel tank, seat, fenders, plastic components.

Lubrication System:

Oil pump, oil passages, oil filter, oil type and capacity.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, coolant checks, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, inspection, component replacement, and reassembly.

Suspension Service:

Fork oil change, seal replacement, rear shock servicing, linkage bearing maintenance.

Brake System Repair:

Caliper rebuild, master cylinder overhaul, line replacement, bleeding procedures.

Electrical Diagnostics:

Wiring diagrams, component testing, fault finding for electrical systems.

Fuel Injection Tuning:

Basic adjustments and diagnostic procedures for the EFI system.

Frame And Steering:

Steering head bearing replacement and adjustment.

Technical Depth

Depth:

Comprehensive, suitable for both amateur mechanics and professional technicians.

Diagrams Illustrations:

Includes detailed exploded diagrams, wiring schematics, and step-by-step procedural illustrations.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Clearances Tolerances:

Specifications for essential component clearances and wear tolerances.

📊 Manual Specifications

File Format

File Type:

Print Quality

Quality:

High-resolution, printable pages with clear text and sharp images/diagrams.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

Searchability

Text Search:

Likely searchable text, allowing quick navigation to specific topics.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, single-cylinder (LC4 engine family)

Displacement:

654 cc (Actual displacement for 2010 model may vary slightly based on specific market tuning, but commonly quoted as 654cc)

Bore X Stroke:

102 mm x 80 mm

Compression Ratio:

12.4:1 (Approximate)

Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 60-63 hp @ 7500 rpm (Varies based on market regulations and specific tuning)

Torque:

Approximately 60-62 Nm @ 6000 rpm (Varies based on market regulations and specific tuning)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Keihin throttle body (e.g., 46mm)

Fuel Type:

Unleaded gasoline, RON 95 or higher recommended

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh gearbox

Clutch:

APTC Slipper Clutch, hydraulically operated

Features

Final Drive:

X-ring chain 520, rear sprocket (e.g., 45 teeth), front sprocket (e.g., 15 teeth)

📐 Dimensions

Exterior

Length:

Approx. 2330 mm (91.7 in)

Width:

Approx. 880 mm (34.6 in) at handlebars

Height:

Approx. 1450 mm (57.1 in) at seat (unladen)

Wheelbase:

Approx. 1480 mm (58.3 in)

Ground Clearance:

Approx. 285 mm (11.2 in)

Seat Height:

Approx. 915 mm (36.0 in)

Weights

Dry Weight:

Approx. 140 kg (308.6 lbs)

Fuel Tank Capacity:

12 liters (3.17 US gal), including a reserve of approx. 1.5 liters

🛡️ Safety Features

Ratings

Safety Certification:

Road-legal, CE compliant where applicable.

Active Features

Optional ABS system, often disengageable for off-road use.

Lighting:

Halogen headlight, LED taillight and brake light.

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame, known for strength and rigidity.

💡 Technology Features

Infotainment

Dashboard Display:

Digital LCD display showing speed, RPM, gear indicator, fuel level, clock, trip meters, and warning lights.

Driver Assistance

ABS Functionality:

If equipped, ABS offers a critical safety layer, especially on pavement. The ability to deactivate it is crucial for off-road control.

Connectivity

ECU Control:

Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 km (3,100 miles) or 12 months, whichever comes first.

Air Filter Service:

Inspect every 5,000 km (3,100 miles), clean/replace as needed based on operating conditions.

Spark Plug Replacement:

Typically every 10,000-15,000 km (6,200-9,300 miles).

Valve Clearance Check:

Typically every 10,000 km (6,200 miles) or as per manual recommendation.

Chain Maintenance:

Lubricate and adjust chain tension every 500 km (300 miles) or after riding in wet/dirty conditions.

Fluid Specifications

Engine Oil Type:

Synthetic motorcycle oil, SAE 10W-50 or SAE 15W-50 (API SG/SH/SJ or JASO MA/MA2 recommended).

Engine Oil Capacity:

Approx. 1.7 liters (1.8 US qt) for oil change with filter.

Coolant Type:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Fork Oil Type:

Suspension fluid, viscosity typically SAE 5W or 7.5W (specific type detailed in manual).

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals can be subject to wear due to demanding use.

Potential Engine Concerns:

Some owners have reported occasional issues with the electric starter motor or charging system, though generally robust. Regular maintenance is key.

Throttle Body Cleaning:

Periodic cleaning of the throttle body can help maintain smooth engine response.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road and racing heritage, originating from Austria.

Model Evolution

Lineage:

The 690 Enduro R evolved from KTM's long history of producing potent single-cylinder dual-sport motorcycles, building on the LC4 platform's reputation for power and durability.

2010 Updates:

The 2010 model typically featured refinements to the LC4 engine, suspension, and chassis, maintaining its position as a premium adventure/off-road machine.

Production

Manufacturer:

KTM Sportmotorcycle AG

Production Location:

Austria

🏆 Awards & Recognition

Recognitions

Industry Reputation:

KTM motorcycles, including the 690 Enduro R, are highly regarded in the adventure and off-road communities for their performance and build quality.