KTM 690 Enduro R EU 2014 Manual

SETUP INSTRUCTIONS 2014

690 Enduro R EU

690 Enduro R AU/GB

690 Enduro R US

Art. no. 3213154en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of supply.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2

1.1 Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

100302-01

–Remove the box and the plastic packaging.

Info

To avoid damaging the motorcycle during assembly, leave the protective film

on the vehicle until you have finished.

–Check the vehicle for transport damage.

–Unpack the separate enclosure and check its contents on the basis of the enclosure

list.

100303-01

–Remove the controls from the transport holder. Remove the screws and handlebar

clamps. Remove the transport holder.

100318-10

–Remove the M8 screw from the right hand guard.

100306-10

–Position the controls on the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

100305-10

–Position the handlebar.

The mark 1of the scale on the handlebar should be centered on the handlebar

clamp.

–Position the handlebar clamps. Mount and evenly tighten the four screws.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

100307-01

–Position the controls on the left half of the handlebar. Mount the screws.

2 SETUP 4

100309-01

–Mount and tighten the rear mirror adapter and rear mirror on both sides.

–Exactly position all controls on the handlebar. Tighten all screws.

–Fit and tighten the M8 screw of the right hand guard.

100308-01

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Pliers for footrest spring (58429083000)

–Remove the protective plastic.

–Carefully loosen and remove the tensioning belt over the link fork.

Info

An assistant prevents the motorcycle from falling over.

–Carefully loosen and remove the tensioning belts around the lower triple clamp.

The vehicle is released at the front.

–Together with an assistant, take the vehicle off the palette.

B00247-12

–Recharge the battery. ( p. 6)

–Connect plug to the starter relay.

B00248-10

–Remove the rear fairing. ( p. 9)

–Four markings can be seen on the underside of the rear fairing. At these posi-

tions, drill holes in three steps of the prescribed size.

Guideline

Hole diameter for grab handles 14.50 mm (0.5709 in)

B00249-10

–Remove screws .

–Fit the rear fairing. ( p. 10)

700217-01

–Mount the reflector.

2 SETUP 5

B00250-10

–Insert the rubber sleeves in the footrest bracket.

–Position the engine guard. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Operation as 2-seater

–Fit the rear footrest bracket. ( p. 10)

Operation as 1-seater (at customer request only)

–Mount the rubber strap for the side stand. ( p. 10)

Warning

Forfeiture of homologation and insurance cover The vehicle is

homologated as 2-seater. If the heel protector is fitted instead of the

footrest bracket, the vehicle no longer conforms to the homologation and

must not be operated in this form without alterations to the registration

papers.

–Set up and operate the vehicle as a 2-seater or have changes made

to the registration papers.

–Fit the heel protector. ( p. 10)

–Refuel. ( p. 11)

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

–Set kilometers or miles. ( p. 12)

3 WORK 6

3.1 Removing the seat

B01948-10

–Pull on strap and raise the rear of the seat at the same time.

–Pull back the seat and lift it off.

3.2 Mounting the seat

B01953-10

–Hook slot of the seat onto screw , press the rear downward and at the same time push it forward.

–Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible

click.

–Finally, check that the seat is correctly mounted.

3.3 Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Warning

Environmental hazard The battery contains elements that are harmful to the environment.

–Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.

Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.

Warning

Environmental hazard Hazardous substances cause environmental damage.

–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Even when there is no load on the battery, it still loses power steadily.

The charging level and the method of charging are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the battery's service life.

If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This

reduces the battery capacity.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the

battery.

The battery is maintenance-free, which means that the acid level does not need to be checked.

3 WORK 7

Preparatory work

–Switch off all power consumers and switch off the engine.

–Remove the seat. ( p. 6)

–Remove the battery. ( p. 7)

100151-10

Main work

–Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the

battery, and to test the alternator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove lid .

Charge the battery with a maximum of 10% of the capacity specified on the

battery housing .

–Switch off and disconnect the charger after charging.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the

motorcycle is not in use

3 months

Finishing work

–Install the battery. ( p. 8)

–Mount the seat. ( p. 6)

–Set the clock. ( p. 12)

3.4 Removing the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Preparatory work

–Switch off all power consumers and switch off the engine.

–Remove the seat. ( p. 6)

B01974-10

Main work

–Remove battery cover .

–Pull the EFI control unit off of the holder and set it to one side.

3 WORK 8

B01975-10

–Disconnect negative cable of the battery.

–Take off the positive terminal cover and disconnect the positive cable from the

battery.

–Remove screws .

–Pull retaining bracket of the battery forward and remove it.

–Lift the battery up and out.

Info

Never operate the motorcycle with a discharged battery or without a battery.

In both cases, electrical components and safety devices can be damaged.

The vehicle is therefore no longer roadworthy.

3.5 Installing the battery

B01975-11

Main work

–Insert the battery into the battery compartment with the terminals facing rearward.

Battery (YTZ10S)

–Position retaining bracket and mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–Position the positive cable and mount and tighten the screw.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–Position positive terminal cover .

–Position negative cable and mount and tighten the screw.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B01976-10

–Position EFI control unit .

–Mount battery cover .

Finishing work

–Mount the seat. ( p. 6)

–Set the clock. ( p. 12)

3.6 Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with

the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with

soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.

Store fuel properly in a suitable canister and keep away from children.

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