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KTM Twins ‘Ultimate’ KTM 690 Adventure Build

Transforming the KTM 690 Enduro R into the ultimate adventure machine!

Published on 08.25.2017


The 690’s lighter weight and excellent off-road capabilities mean it can get into trickier terrain than most adventure bikes. Robust protection is required to ensure it can get out of those situations unscathed. And with this build’s ability to travel even further away from civilization, protecting the vulnerable parts becomes all the more important.

Flatland Racing Skid Plate

KTM 690 Enduro Bike Build Flatland Racing Skid Plate

KTM’s signature trellis frame on the 690 sure looks cool but leaves the belly of the beast extremely exposed. The sleek and simple Flatlands Racing skid plate was selected to protect the vulnerable underside of the engine because it’s made of rugged 3/16″ aluminum, and includes easy mounting and removal for maintenance.

Vanasche Motorsports Case Saver


KTM 690 Enduro Bike Build Vanasche Motorsports Case Saver

Vanasche Motorsports (Formerly Shift Manufacturing) is a small shop that specializes in 690 and 701 parts. Their robust CNC machined aluminum case saver was chosen to protect the Ultimate KTM 690 KTM 690 Enduro’s engine case and clutch slave cylinder. This allows for adjustment of the Rekluse slave cylinder without being removed unlike the stock cover.

Vanasche Motorsports Brake Lever

KTM 690 Enduro Bike Build Brake Lever

Part of this build was eliminating weak links so that this bike could withstand the rigors of off road abuse. One of the obvious things needing to be addressed was the stock brake lever so it was replaced with the solid CNC machined Vanasche part. Like their case saver, it is not only a big upgrade in looks but also more durable on the trail.

Fasst Company Simple Solution Hand Guards

KTM 690 Enduro Bike Build Hand Guards, Brake Lever and Mirrors

The only real downfall of Fasst Company Flexx Bars is their lack of compatibility with most hand guards due to their flexing design. Fasst Company worked directly with Enduro Engineering to develop hand guards specifically for their bars so they made perfect addition to the build.

Double Take Mirrors

The stock mirrors on the KTM 690 Enduro are a bit of a weak point with planned usage for this bike being primarily off-road travel. A small tip over or clipped branch can easily lead to a broken stock mirror but DoubleTake Adventure mirrors, with their breakaway design, are virtually invulnerable to trail abuse while still offering excellent rear visibility.


A durable soft luggage system that provides adequate room for body movement is key for overland travel. And when you are living on your bike for days on end, it’s important that you have good capacity to carry all the necessities for comfortable camping.

KTM Luggage Racks with Wolfman Soft Luggage

KTM 690 Enduro Bike Luggage Racks and Wolfman Luggage

This bike was made to travel so it is outfitted with KTM luggage racks sporting the new Wolfman Luggage Pikes Peak mounting plates. Since this bike is slated for heavy off road use and extended overland trips, the luggage needed to be durable and have good capacity. Wolfman Luggage’s sturdy and spacious bags fit the bill: Rocky Mountain saddlebags, Expedition Dry Duffel (Medium) and Enduro tank bag were used. This combination allows for ample storage on long trips and is tough enough for any difficult terrain traversed.

Perun Moto Rack with Extension Plate

KTM 690 Enduro Bike Luggage Rack and Extension Plate

Perun Moto is a small company out of Serbia that makes well thought out pieces for the 690 and 701. Their luggage rack is in its second iteration and was chosen for its large surface area (with the extension plate), plentiful tie down points and integration with the KTM luggage rack.


Suspension is one of those things that can always be improved no matter how good the stock components are. Coming from the factory, OEM suspension components can’t accommodate every riders weight or riding style. A high-quality aftermarket suspension offers a more responsive, compliant ride when riding on rocks and roots, along with increased firmness to handle any big whoops and g-outs.

Konflict KM2 Front Fork Custom Revalve & Respring

KTM 690 Enduro Bike Konflict KM2 Front Fork Custom Revalve

The suspension experts at Konflict Motorsports performed their popular KM2 Fork Revalve, then sprung it for the riders weight with gear. A pair of KTM SXS Preload Adjustable Fork Caps were also added to allow for front sag adjustments without taking apart the forks.

Konflict KM2 Rear Shock Custom Revalve & Respring

KTM 690 Enduro Bike Konflict Motosports suspension

Konflict performed a KM2 Shock Revalve on the rear shock and resprung it for the riders weight with gear. Konflict also added a Tractive Hydraulic Preload Adjuster to enable fine tuning of preload by hand for various load weights, and beefed up the rear linkage with a heavy-duty Rally Raid Pivot Pin.


What would the Ultimate 690 be without any performance upgrades other than just a big farkle fest?

Rottweiler Intake, Canister Removal, O2 Plug and Crankcase Breather Kit

KTM 690 Enduro Bike Rottweiler Air Intake and DynoJet Power Commander

Due to the location/design of the air box on KTM 690 Enduros, they have sealing issues with the filter that can allow sediment to enter the engine. The snorkel design also seriously limits air intake volume, hindering performance. Rottweiler specializes in rectifying these types of problems on KTM’s and improving performance. Their complete 690 kit replaces the bulky stock intake and gives the bike a serious performance boost (+12.101 HP / +12.716 TQ at 5,000 rpm!). It is an essential upgrade for any 690, not only increasing performance but also making maintenance easier and ensuring nothing but clean air makes it into the motor.

DynoJet Power Commander V

To harness the power of all the aftermarket add-ons, a PCV was used with a pre-programmed map by Rottweiler Performance. This upgrade takes any guesswork out of programming the unit so that it works flawlessly out of the box. The benefit of this unit is not only additional power but also better throttle response and smoother idle. Check out our review of the DynoJet Power Commander V for more details.

KTM Off Road Dongle (ABS Dongle)

With the ABS being enabled every time the ignition is cycled, this ingenious little “dongle” allows the rear ABS to remain off and the front to remain on. So essentially you can start the bike and be ready to ride off road without having to stop and put the bike in neutral to disengage ABS for both tires. This dongle also allows for ABS to be fully enabled as the secondary setting, turning it on just like you would normally turn off ABS with stock configuration.

Arrow Exhaust Header, Mid-Pipe and Titanium Silencer

KTM 690 Enduro Bike Build Arrow Header and Titanium Silencer

A better flowing engine is a happy engine! With Rottweiler covering the intake, a full Arrow exhaust system was used to round out performance. This system is attractive due to the weight reduction over stock, horsepower gains and of course the exhaust note! The titanium silencer with carbon end cap looks worlds better than the factory unit and has a much deeper tone.

Rekluse Radius X Auto Clutch

KTM 690 Enduro Bike Build Rekluse Radius X Auto Clutch

The Rekluse Radius X Auto Clutch utilizes their patented EXP clutch disk that uses centrifugal force to engage and disengage the clutch without the use of the clutch lever. The rest of the clutch pack is made up of Torque Drive disks that boast longer life and increased power transfer (more torque!). Standard clutch lever function with full override is retained but with the ability to never stall. Its hard to imagine ever wanting to go back!

Scott’s Steering Stabilizer with BRP Sub Mount

KTM 690 Enduro Bike Build BRP Sub Mount/Scott’s Steering Stabilizer

This is a BIG upgrade in a small package: The BRP Sub Mount uses polyurethane bushings to minimize vibration, raises the bar height to a more off road friendly height (approximately 2″) and is the mount for the Scott’s Steering Stabilizer. The Scott’s unit is the magic savior hand that swoops in and saves your bacon when you are riding in any sandy or loose conditions. It also diminishes head shake at high speeds..

➤ Click Here For Build Sheet

Photos by Spencer Hill

Author: Spencer Hill

“The Gear Dude” has been fueling his motorcycle addiction with adventure since first swinging his leg over a bike in 2010. Whether he’s exploring his own backyard in the Pacific Northwest or crisscrossing the United States, Spencer is always in search of scenic off-road routes, epic camping locations and the best gear possible. He began writing shortly after taking up two-wheel travel to share his experiences and offer insight with his extensive backpacking, camping and overland background.

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Author: Spencer Hill

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27 thoughts on “KTM Twins ‘Ultimate’ KTM 690 Adventure Build

  1. Wow! Just what I was looking for. Totally worth a read. I’m planning to buy a KTM690 Enduro R from quite sometime now, but my height is 170cms, is it possible to lower the seat height.? how feasible it is to change the wheels set up from 21front &18rear to 19 front & 17 rear??

      • I have a 2013 R and I’m 5’7. I had Race Tech lower the forks and rear shock with spacers, custom springs 1 inch. I also placed a seat concepts saddle off a 2010 which lowers it another 10mm.

  2. For a grand total of $10,107.00. Did you get a “blank check” of someone else’s money? “Here, build what you think will be an Ultimate build, and get back to me.”

    It’s a great build, along with all the labor to install all that, and sort out what will / will not fit together.

    I hope it was fun, not soul crushing.

    I also hope you never have to sell it.

  3. I think that I would call it a Rally Build before I would call it an Enduro Build. And I’ll bet the “Wet” or “Curb” weight is about 360 lbs (164 kg).

    • MmmHmmmm. That was before adding 2+ gallons of gas and all the goodies. What do you guess wet weight is now? Over 380? (+ for gas, – for exhaust).

      I would certainly like to know what it weighs now.

      I’ll consider it when the redesigned motor makes it onto the 690 platform. This was a very nice build out, and offers many truly good upgrades / fixes for known 690 issues. Very Nice…

      But, the T7 is due now, very soon 🙂

      • Hey Bob, I would like to believe the Yamaha will be light, but realistically I would be surprised if it’s under 450 lbs by the time it makes it to market. The KTM may be more expensive, but hp and light weight doesn’t come cheap. Yes, this build was pricey, but you don’t have to do everything Spencer did. This build was about what CAN be done using the KTM Twins parts catalog.

  4. Pingback: KTM Twins Ultimate 690 Enduro Build Sheet - ADV Pulse

  5. That’s an awesome build. Very functional and great looking. But, what about getting some Trailjammer Designs Clutch Cover and Stator Cover Guards on there? 🙂 Protect that engine from a rock puncture when you tip over. Great write up too! Good job Spencer!

  6. Hi Spencer – Beautiful bike. I saw you mounted the Fasst Impact Pegs, which I love, but I ordered them for my 2017 690 Enduro and they’re not compatible. Could you please take the time to let me know how you got them to fit? Thank you in advance.

  7. Great Build. What model or degree rise did you get for the Fasstco handlebars. How did you like the way they meshed with the Steering damper? I am looking to do the same on my 2017 701. Thx Brian

  8. Curious about your opinions on the luggage… Here you list the Wolfman bags with the hard side luggage racks; why did you choose that over the Mosko BackCountry 35 like you used previously or even the Mosko Reckless 80 without any side racks on the bike?

    • On this build I used hard luggage racks because I wanted the extra protection. As far as luggage selection goes I was eager to test the Wolfman Pikes Peak Plates with Rocky Mountain saddlebags to see how they compared.

  9. I’m currently kitting up a 2017 model year 690 Enduro R.

    I was surprised to discover that the uber expensive MST EVO2 Adventure Rally part, does NOT include the RR fuel tanks. It’s fairing and tower, but no gas tanks.

    They say it will *fit over* the RR tanks, but you have to buy them.


  10. WOW what a great looking bike and only 12K in addition to the cost of the bike. They come from the factory “Ready to race” but evidently not ready to BDR lol.

  11. Pingback: Adv Bike – Wallpaper Site


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