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KTM 690 Enduro R 2010 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: KTM Model: 690 Enduro R Year: 2010 Vehicle Type: Dual-Sport Motorcycle Codes Chassis Code: KTM 690 Enduro R (2010) Engine Code Prefix: LC4 👋 Introduction...
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类型: Motorcycle
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KTM 690 Enduro R 2010 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
KTM
Model:
690 Enduro R
Year:
2010
Vehicle Type:
Dual-Sport Motorcycle
Codes
Chassis Code:
KTM 690 Enduro R (2010)
Engine Code Prefix:
LC4
👋 Introduction
Market Position
Segment:
Lightweight, go-anywhere dual-sport motorcycle positioned for riders seeking off-road capability with street legality.
Target Audience:
Adventure riders, dual-sport enthusiasts, commuters seeking ruggedness and versatility, and off-road riders who need occasional street use.
Competitive Analysis
Key Competitors:
BMW G 650 GS Sertão, Yamaha WR250R, Kawasaki KLR650, Honda CRF250L (though generally less off-road focused).
Key Features
Engine Characteristics:
Torquey single-cylinder LC4 engine, known for its strong low-end and mid-range power delivery, suitable for both trail riding and highway cruising.
Suspension And Chassis:
Premium WP Suspension components offering excellent adjustability and travel for off-road prowess. Lightweight trellis frame.
Ergonomics And Design:
Designed for stand-up riding with ample ground clearance and rider triangle conducive to off-road control.
Off Road Focus:
Spoked wheels, robust bash plate, higher exhaust routing, and knobby-capable tires indicate a strong emphasis on off-road performance.
📋 Manual Details
Coverage Areas
Coverage:
Complete factory service and repair coverage for the 2010 KTM 690 Enduro R.
Page Count
Page Count:
Hundreds of pages (estimated 300-500 pages based on typical factory manuals of this scope).
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English (assumed typical for international markets, confirmation required if other languages are critical).
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine And Drivetrain:
Complete engine disassembly, assembly, inspection, troubleshooting, and repair procedures for the LC4 engine. Includes fuel system, ignition, lubrication, cooling, and exhaust.
Chassis And Suspension:
Front forks (WP Suspension), rear shock absorber (WP Suspension), swingarm, linkage, steering head, wheel bearings, and frame inspection.
Brakes:
Front and rear brake system inspection, repair, bleeding, component replacement (calipers, master cylinders, lines, discs), and ABS system (if equipped).
Electrical System:
Wiring diagrams, component testing, battery, starter, alternator, lighting, sensors, ECU diagnosis, and instrument cluster.
Fuel System:
Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), diagnostics, and adjustments.
Bodywork And Ergonomics:
Fairings, seat, fuel tank, fenders, handlebar, footpegs, and general cosmetic component removal and installation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable via diagnostic tools).
Major Repairs:
Engine rebuilds, gearbox overhauls, suspension component overhauls, brake system overhauls, and electrical system repairs.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, ensuring clarity of text, diagrams, and images. Searchable text for easy navigation.
Print Quality
Printability:
Designed for full or partial printing, allowing users to create physical copies of specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital PDF format).
Paper Type
Paper Type:
N/A (Digital PDF format).
Completeness
Content Scope:
Complete, encompassing all aspects of the 2010 KTM 690 Enduro R as designed and serviced by the factory.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled, DOHC
Displacement:
657.5 cc
Bore X Stroke:
102 mm x 80 mm
Compression Ratio:
12.3:1 (approx.)
Performance
Horsepower:
Approx. 63 hp @ 7,500 rpm (Factory spec may vary slightly)
Torque:
Approx. 60 Nm (44.3 lb-ft) @ 6,000 rpm (Factory spec may vary slightly)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Keihin throttle body (typically 46mm)
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Lubrication
Oil Capacity With Filter Change:
Approx. 1.4 Liters (1.5 US qt)
Recommended Oil Grade:
SAE 10W-50 (or as per owner's manual, e.g., Motorex Power Synt 4T)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0)
🔧 Transmission
Standard
Type:
6-speed, claw-shifted
Clutch Type:
Wet multi-disc clutch, hydraulically operated
Features
Final Drive:
X-ring chain, 525 pitch
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 32/14, 2nd: 30/17, 3rd: 28/19, 4th: 25/21, 5th: 22/23, 6th: 24/27)
Transmission Oil Capacity:
Approx. 1.1 Liters (1.16 US qt)
Transmission Oil Grade:
SAE 75W (or as per manual, often similar to engine oil grades for shared sump systems, but confirmation is vital)
📐 Dimensions
Exterior
Length:
Approx. 2330 mm (91.7 in)
Width Without Mirrors:
Approx. 860 mm (33.9 in)
Height Seat:
Approx. 930 mm (36.6 in)
Ground Clearance:
Approx. 285 mm (11.2 in)
Weights
Dry Weight:
Approx. 146 kg (321.9 lbs)
Ready To Ride Weight Approx:
Approx. 160 kg (352.7 lbs) (with all fluids, without rider)
Gross Vehicle Weight Rating Gvwr:
Refer to chassis plate or manual (typically around 300-350 kg)
Wheels And Tires
Front Wheel Size:
21 x 1.85
Rear Wheel Size:
18 x 2.50
Front Tire Size:
90/90-21
Rear Tire Size:
140/80-18
Wheel Bolt Pattern:
N/A (Spoked wheels with bolt-on hub carriers)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles are generally not subjected to standardized crash testing like automobiles. Safety is primarily judged by design, equipment, and rider skill.
Active Features
Brakes:
Front: Single 300mm disc with 4-piston radial caliper; Rear: Single 240mm disc with 2-piston caliper. ABS available on some variants, consult manual for specifics.
Lighting:
Halogen headlight, LED taillight and indicators, ensuring visibility.
Handling:
Advanced suspension geometry and high-quality components contribute to stable and predictable handling.
Passive Features
Frame:
Strong steel trellis frame designed for rigidity and impact absorption.
Bodywork:
Durable plastics designed to withstand minor impacts and abrasions.
Ergonomics:
Handlebar design and control placement optimized for rider input and stability.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD display providing speed, RPM, odometer, trip meters, fuel level, gear indicator, and warning lights. The manual will cover its functions and troubleshooting.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an option or standard on certain markets for the 2010 model. The manual will detail its operation, disabling, and troubleshooting if equipped.
Connectivity
Diagnostics:
The manual will outline diagnostic procedures, potentially including information on accessing error codes through the instrument cluster or via an OBD-II interface if applicable for ECU readings.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first. Consult manual for precise intervals.
Air Filter Cleaning:
Recommended every 5,000-7,500 km (3,000-5,000 miles), or more frequently in dusty conditions.
Valve Clearance Check:
Typically at 10,000-15,000 km (6,000-9,000 miles) intervals. Crucial for maintaining performance and preventing damage.
Chain Maintenance:
Clean and lubricate every 500-1,000 km (300-600 miles) and adjust tension as needed. Check for wear.
Fluid Specifications
Engine Oil Grade:
SAE 10W-50, JASO MA/MA2 approved synthetic motorcycle oil (e.g., Motorex Power Synt 4T).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically pre-diluted 50/50 with distilled water (e.g., Motorex Coolant M3.0).
Brake Fluid Type:
DOT 4 (or as specified in manual), for both front and rear brake systems.
Clutch Fluid Type:
DOT 4 (or as specified in manual), for the hydraulic clutch system.
Known Issues
Fuel Pump Reliability:
Some early models or units with certain fuel types experienced occasional fuel pump issues. The manual will detail diagnostic and replacement procedures.
Engine Vibration:
As a large single-cylinder, the LC4 engine can produce noticeable vibrations. Proper engine mounting and balancer shaft operation are key, covered in the manual.
Suspension Seals:
Heavy off-road use can stress fork seals. Regular inspection and maintenance, detailed in the manual, are crucial.
Electrical Connections:
Ensuring clean and secure electrical connections is vital, especially given the vibration and exposure to elements. The manual's wiring diagrams are invaluable.
📚 Vehicle History
Brand Heritage
Ktm Legacy:
KTM has a strong heritage in off-road racing, particularly in motocross and enduro, which informs the design and engineering of their dual-sport and adventure models.
Model Evolution
Lc4 Lineage:
The 690 Enduro R builds upon KTM's long-standing 'LC4' single-cylinder engine platform, known for its robust nature and adaptability across various KTM models.
Enduro R Positioning:
The 'R' designation typically signifies a more performance-oriented or off-road focused version of the standard model, featuring enhanced suspension and other upgrades.
Production
Manufacturing Location:
Primarily Austria (Mattighofen), KTM's headquarters and primary manufacturing hub.
Model Run Years:
The 690 Enduro R has been produced in various iterations since its introduction, with significant updates over its lifespan.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2010 model year are hard to pinpoint without dedicated historical search, the 690 Enduro R generally receives praise from motorcycle publications for its off-road capability and powerful single-cylinder engine within the dual-sport category.
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