Complete KTM 690 Enduro R Build – My Adventure Setup Project
In this post, I’m putting everything in one place — what I changed, why it makes sense for TET/ACT, and how it works in real life.
If you’re just thinking about a 690 or you already own one and want to build it “ready to go” for adventure — treat this as inspiration and a checklist. I’ll keep it concise and practical.
Why a brand-new bike and where it’s from
I bought a brand-new KTM 690 Enduro R at Wojciechowicz dealership (ktmsklep.pl) because I wanted peace of mind: fewer repairs, more riding. Newer model years handle vibrations better and have improvements that older bikes sometimes lacked. In practice: less risk and more confidence on longer trips. Buying new also means I can break the engine in properly myself — and I know nobody abused it or poured “cooking oil” into it.
If you’re looking for KTM parts and accessories — I have a permanent discount at KTM-Sklep with code Kewin10.
KTM Shop offers a wide selection of original KTM parts and accessories for motorcycles and KTM ATVs, as well as Motorex oils and chemicals.
You’ll find interactive parts diagrams that let you order quickly and easily from your phone or computer.
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Project foundation: Rade Garage (tower + tank + protection)
This is the base of the whole build. On my bike, Rade Garage does the key things: more range, cockpit/navigation, and protection + organization.
Rade Garage 5L under-seat auxiliary fuel tank
An extra 5 liters gives me realistically about +100 km of range. For me it’s the “difference between relaxed and stressed”:
- on long transfers (e.g., riding back from Greece to Poland on the highway) I refuel less often,
- in areas with no fuel stations I have a safety buffer.
A very important detail: the fuel tap.
- If you keep it open — fuel drains evenly and the center of gravity stays lower.
- If you want a “last-resort reserve” — you close it, run the stock tank, then open it and you’ve got the full 5L in reserve.
Install bonus: performance intake and air filter
When you install the tank you also get a performance intake and air filter — improved airflow, and you can feel the engine “breathing easier.” The filter is foam, so it’s straightforward: clean it regularly. I do it often after a week of offroad riding and I keep a few filters in rotation (remove dirty one, install a freshly oiled clean one).
Installation? You can get it done in one evening / one day — more “bolts and patience” than heavy fabrication.
Rade Garage Rally Tower (cockpit, lights, wiring)
Rade Garage K5 Fairing is one of those mods that truly changes the character of the KTM 690: better wind protection, rally ergonomics, and a clean cockpit — without killing the bike’s lightweight feel.
The rally tower has many advantages:
- rally looks (cool, but secondary),
- better wind protection — much better comfort on transfers,
- powerful LED lights and easy low/high beam adjustment.
- The tower is a platform for accessories: you get a phone/tablet/GPS bar; easy access to wiring, fuses, and all electronics “in one place”; cables are hidden — nothing tangles, everything is tidy and serviceable.
I also added a panel with extra USB ports (I drilled the hole in a replaceable part). My tablet is wired so that charging works with ignition: I start the bike and everything powers up automatically.
Detailed component breakdown
- Windscreen — reduces wind resistance and fatigue on transfers while staying out of the way offroad.
- Polycarbonate side panels — flexible side protection from mud and minor impacts while keeping the 690 slim.
- Carbon fiber tower — light and strong central structure for the cockpit that reduces front weight and provides a solid base for devices; plus a lifetime warranty. https://www.radegarage.com/lifetime-guarantee/
- GPS bar + adapter — a stable bar for mounting electronics (GPS/phone/tablet), designed for easy installation and a clean line of sight.
- LED lights (ECE) — powerful, road-legal dual-beam LEDs that offer much better night visibility than the stock headlight.
- Mounts and wiring — complete set of connectors, electrical adapters, and bolts to mount the fairing without drilling or permanent mods.
- Steering damper adapter (Scotts) — dedicated mount so a Scotts damper fits straight into the cockpit without custom brackets.
It’s a complete kit that makes the KTM 690 more comfortable, cleaner, and more offroad-friendly, focused on real devices and aero protection — not just looks.
Rade Garage skid plate with tool storage
This is one of my favorite parts: protection + storage. The Rade Garage Skidplate EVO2 does far more than just “protect the underside” — it’s a heavy-duty skid plate combined with a practical tool box, designed specifically for real offroad use. It protects the engine and undercarriage from rocks, stumps, and impacts, while letting me carry the heaviest and most annoying essentials (tube, tools, emergency kit) low, centralized, and without taking space in my luggage. That improves stability, and I always have the critical stuff within reach — exactly where it makes sense for TET/ACT.
What I carry inside:
- spare tube,
- tire tools,
- folding side-stand foot (when there’s no tree to lean the bike on),
- tape, cordage, straps and “stuff that always comes in handy” that you don’t want inside your bags.
This skid plate also comes with rear brake master cylinder protection.
I even have a slightly crazy idea: one day convert it into a water reservoir (bag + hose). The reason is simple: I don’t like hydration packs on my back — I prefer to keep my back free.
Navigation control: Carpe Iter (Bluetooth)
Carpe Iter is a navigation controller — I operate it with my thumb via a joystick: centering, zoom in/out, moving the map. It lets me control the map while riding, which is insanely useful. I can quickly preview what’s coming next, analyze an alternative route, etc.
I chose the Carpe Iter controller because it’s the narrowest joystick on the market. Thanks to its compact shape, I still have easy access to the turn signals.
I wired power through a switch on the tower, so I can keep the controller on even when the bike is off (e.g., during a stop).
Carpe Iter is the missing link between “classic navigation” and real offroad riding — a system that lets me control maps and tracks without touching the screen, in gloves, on bumps, and in the rain. The joystick and buttons are intuitive and responsive, and it eliminates fiddling with a tablet when I should be watching the trail. Combined with the app, I get full control over GPX tracks, map centering, zoom — without taking my hands off the bars.
Peak Design wireless charging
There are many phone mounts on the market — I’d say I’ve tried half of them: RAM Mounts, Quad Lock, and finally the most refined and genuinely user-friendly system: Peak Design.
The Peak Design mechanism is the heart of the whole system and the main reason I use it: SlimLink™ combines ultra-strong magnets with a mechanical lock, so the phone “snaps” into place and is physically secured — it won’t detach on potholes, washboard, or sand.
It’s fast and intuitive: you mount and remove the phone one-handed, without looking, even with gloves. Release is done with a single tactile button. The vibration isolator is also key — it filters high-frequency vibration that can damage camera stabilization, while staying rigid enough to use the screen normally when stopped. Everything feels precise, with no play or “rubberiness,” which is rare: maximum security plus very fast access.
The lock/unlock mechanism is in a different league. With Peak Design you can release the phone with one finger from either side. I talk a bit more about it in this video:
Pro Grip 786 ROAD RALLY (foam grips)
Pro Grip 786 Road Rally are rally-style foam grips designed for long distances and offroad riding. In practice they significantly reduce vibration and hand fatigue thanks to the soft, sponge-like material that absorbs vibration and provides a secure, non-slip grip even in wet conditions. The foam also reduces the risk of hotspots and blisters on longer rides, which translates to comfort and control all day.
Foam Pro Grips deliver:
- noticeably better vibration damping,
- comfort and a pleasant feel,
- on my bike: no glue, pressed on and safety-wired so they don’t rotate.
The biggest advantage is simple: I stopped getting pressure marks on longer trips. Foam grips don’t last forever — you’ll probably replace them every couple of seasons — but they’re cheap and easy to install.
But what about heated grips?
I’m skipping heated grips for one reason: they’re noticeably thicker, which reduces grip security. Even though I have long fingers, thick grips make it harder to hold the bars properly offroad.
And in cold weather? I always carry cheap ski gloves — they work отлично even on highway transfers around zero degrees.
Dope Mirrors – an off-road compromise that works
Dope Mirrors are, for me, a well-thought-out compromise between off-road and normal riding — they’re solid and flexible enough to fold away offroad and survive a crash without stress, while still offering a large field of view that you actually use on asphalt and long transfers.
The biggest advantage is the visibility. They’re big and show far more than the small round Vicma mirrors I used before. And compared to the stock ones — no contest.
Off-road benefits:
- you can fold/lock them for off-road,
- the arm is flexible enough to be forgiving in a crash,
- in the newest version the arm is metal (lower risk of damage).
The Dope Mirrors design uses an arm on two ball joints, so on a big single-cylinder, vibration and aggressive riding will eventually loosen the mirror position a bit. Tightening the screw properly gives you hours of riding without adjustment, but you should expect occasional tweaks. It’s not a big deal — especially because when pushing through bushes and branches, the mirrors can fold instead of catching and wrenching the bars.
Folding or even removing the mirrors completely changes the steering feel — also a great advantage if you plan to ride a track or a rally.
Scotts steering damper – mandatory
This isn’t a “gadget” — it’s an accessory that truly takes load off your hands and forearms, damps sudden bar reactions over bumps, landings, and traction changes, and makes a massive difference in stability both on fast gravel and in technical terrain. It reduces hits and vibration transferred to the wrists, which means less fatigue on long days, and less “bar slap” when the front wheel finds mixed grip — especially where the stock setup would be twitchy. In practice it also improves confidence in turns and on faster dirt sections because the bike is easier to manage without fighting the front end.
If you ride travel enduro/ADV or plan long distances mixing asphalt and offroad, I treat a Scotts damper as a must-have for control, comfort, and safety.
For me, Scotts on the 690 is a “must have”:
- reduces load on hands and arms,
- stabilizes the bike,
- protects against hits and front wheel deflections.
Also: if you have the Rade Garage tank, you get the required parts for the Scotts install — less DIY and fewer extra costs.
You can also get this damper on ktmsklep.pl (don’t forget my discount code Kewin10!):
I talked a bit more about this steering damper in a video:
I also wrote a review and proper setup guide here:
Tools: Motohansa Pro Compact 38 PC Tool Kit
What I like about the KTM is that once you remove the seat and side panel you have quick access to tools. I replaced the stock kit with a HansaMoto set — it has everything you actually need to work on the bike on the road.
Motohansa Pro Compact 38 PC Tool Kit (MTT0001-38B) is a compact motorcycle tool kit designed for offroad riding and travel, combining full service functionality with minimal weight and size.
Yakk crash bars and accessories – radiator protection and smart minimalism
Some say the 690 doesn’t need crash bars. I prefer to protect the radiator and vulnerable areas in a fall. Plus, Yakk EXP crash bars for KTM 690 can also serve as mounting points for small accessories or light luggage.
Yakk also offers a fuel filler neck riser with cap, which not only removes the need to unlock the tank with a key, but — more importantly — the design prevents dirt from collecting right at the seal like in the stock solution.
Another accessory I can recommend is the side stand enlarger. Offroad, it’s a must.
Yakk EXP has a huge range of useful solutions and it’s impossible to mention them all here, so check yakkexp.com for everything you need for the KTM 690 Enduro R — and other bikes too.
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Seat Concepts seat – a real difference over distance
I rode the stock seat for a bit and for me it didn’t work — two hours and the fun was over. Seat Concepts (standard height, not raised) solved long-transfer comfort without hurting control offroad. If I were buying today, I’d probably choose the extra grip version.
The Seat Concepts seat on the KTM 690 Enduro R is so comfortable that you can ride for days and barely think about standing up — or worse, stopping for a break.
Expensive, but worth it. No point going halfway.
SAE charging straight from the battery + voltmeter
I have an SAE lead connected directly to the battery with an adapter that shows voltage. The goal:
- I can plug in even with the ignition off,
- on the road I charge a power bank in my tank bag, and in the evening I charge everything else from the power bank.
Simple, but extremely practical for long travel.
Carbon clutch cover guard
The cover gets scratched quickly from your boot, so it’s worth installing a guard as early as possible.
It’s also worth removing and cleaning it occasionally, because dirt can get underneath and act like sandpaper. And be careful with torque — overtightening can damage the threads in the engine cover.
KTM PowerParts Rally footpegs
KTM PowerParts Rally footpegs are wider, longer, and more offroad-focused than the stock pegs — and they make a real difference where control and foot stability matter.
They’re wider and longer, so standing is more stable. Practical tip: with my Kewin10 code on ktmsklep.pl they often end up cheaper than alternatives.
TwinPegs – “weird”, but brilliant
This is an unusual solution: an additional peg creates a large platform for your entire boot. The effect:
- you can stand for a long time and your legs actually rest,
- more stability in sand and rough terrain,
- for my riding style (TET/ACT, mix of hard and easier sections) — it’s perfect.
It’s not a hard enduro solution where you work the heel and absorb aggressively, but for travel enduro/ADV it works exceptionally well.
TwinPegs™
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TwinPegs™ add a second footpeg behind the stock one, improving weight distribution and stability during long offroad rides. They help reduce fatigue, increase control, and improve ergonomics. Ideal for offroad riders who push boundaries.
You can read more about this innovative idea in a separate post:
Perun Moto strap panel/buckle
Perun Moto strap panel/buckle is a practical part that links footpegs, luggage system, and stable load anchoring without adding unnecessary weight.
I kept it even with TwinPegs because Perun’s profile is bent outward — the straps don’t press on the plastics/tank and they don’t route toward hot parts. I’ve seen “flat” alternatives that end up pushing into plastics and causing issues — I don’t recommend them. Perun Moto is designed extremely well.
Perun Moto central luggage rack plate
Perun Moto Luggage Rack SD is a refined luggage base built without compromises: a 6 mm plate and 5 mm support from AlMg3 aluminum, a triangular structure that damps vibrations, smooth strap-friendly edges, and 22 tie-down points for soft luggage. It works with Kriega OS, Mosko Reckless, Rotopax (without removing the rack), and various pannier frames — and it can even replace grab handles for lifting the bike. It weighs only 1.3 kg, uses proper 10.9 hardware, and has a durable powder coat — light, quiet offroad, and simply works on TET/ACT without destroying bags.
For me it’s one of the few racks made the way they should be:
- compatibility with Kriega OS-Base and other top systems,
- a sensible profile and weight,
- excellent finishing: edges are smooth, so they don’t cut straps or bags.
This is critical, because “laser cut + paint and done” racks can slice luggage in real use. I’ve been there — if you can’t afford buying new bags every season, Perun Moto is the only correct solution.
The profile is perfectly matched to the KTM 690 Enduro R tail. It also has two extra rubber bumpers that support the rear when luggage moves.
Fuel dongle PP-02
Fuel Dongle PP-02 is a sensible upgrade for Euro 5 bikes (KTM 690, Husqvarna 701, GASGAS ES700) that fixes an overly lean mixture without touching the ECU. It eliminates low-RPM surging, noticeably improves throttle response in the low and mid range, and also reduces engine and exhaust temperatures. Correcting AFR to an optimal 13.8 makes the bike smoother, calmer, and more predictable — especially in slow offroad and technical sections. Installation is plug & play, no modifications — install and ride, and you feel it from the first kilometers.
Fuel Dongle PP-02 is worth it because it solves real Euro 5 issues without side effects: it doesn’t increase fuel consumption, doesn’t trigger ECU errors, and works with both the stock exhaust and a de-cat setup.
It’s a small module that “tricks” the ECU to add a bit more fuel at low RPM. The effect:
- less bogging and less jerking down low,
- smoother riding in difficult terrain.
Fuel consumption may increase slightly (around 0.2–0.3 L/100 km), but for me the comfort and control are worth it. It’s a clear trade-off: less eco, more usability. To amplify slow technical riding even more, I’m also considering a larger rear sprocket.
How it works
On Euro 5 bikes the stock ECU targets AFR 14.7 at low RPM and small throttle openings, which in practice means higher temperatures, surging, and a nervous throttle response. Fuel Dongle PP-02 corrects the signal and brings the mixture down to an optimal AFR ~13.8, so the engine runs cooler, smoother, and more stable, and throttle response in the low and mid range improves clearly. The difference is immediate — especially in slow offroad, traffic, and technical sections where control matters more than emissions targets.
Fork socks – cheap insurance after a leak
I learned this “after the fact.” If you ride mud and grime, dirt can get under the seals and cause leaks. Fork socks for a few bucks are simple protection worth having.
Kriega OS (OS-18 / OS-12 / OS-6) – modular luggage
Kriega OS (OS-18 / OS-12 / OS-6) is modular luggage that I adapt to the route — not the other way around. I choose small, medium, or larger bags depending on distance and terrain. The system is tough, 100% waterproof, and stable offroad. Thanks to modularity, I can ride ultra-light or add capacity without changing the whole setup. The bags sit low and close to the bike, don’t flop around offroad, and don’t interfere when standing. It’s pure functionality for TET and ACT: zero compromises, fast packing, and full control over how much I actually carry.
It works on the KTM and other bikes too. I’ll make a separate piece about packing and configurations because it’s a deep topic.
Barkbusters – proven, so they stay
A classic that just works. On the 690 I had to improvise a bit with the mounts (swap sides / one “upside down”) because I couldn’t find a perfectly dedicated kit and I wanted to avoid interference with the clutch and brake.
Barkbusters saved me many times from snapping a lever on my T7. On the KTM I haven’t had the “chance” to test them yet — but the trust factor is proven by one thing: I don’t carry spare levers.
Wings exhaust – on the 690 it’s not a “mod”, it’s a necessity
On the KTM 690 you shouldn’t keep the stock exhaust because it’s heavy, bulky, and — most importantly — it gets so hot it can melt the stock plastics and luggage. I’ve seen it with my own eyes.
A Wings exhaust on the KTM 690 is a mandatory upgrade, not an option — lighter, cooler, and far more sensible than the stock can. The overheating issue for plastics and luggage is gone, you drop weight high at the rear, and the engine feels smoother with a deeper, nicer sound without being obnoxious. With the longer dB killer it stays civilized, yet you can tell the bike breathes more freely. It improves ergonomics, luggage safety, and riding comfort — without turning the 690 into a loud gimmick.
Wings gives you:
- a few kilos less,
- better sound (stock 690 sounds like a scooter to me),
- real temperature improvements.
It’s also worth getting the longer tip / bigger dB killer — it still sounds good but it’s quieter. This matters: you don’t terrorize forests, you don’t annoy people, and you protect your own hearing. I also run a heat shield (Acerbis) “just in case,” but with Kriega and correct spacing there’s plenty of clearance — nothing melts.
Tires: Mitas Enduro Trail Rally Pro
This is the question I get most often: which tires for the KTM 690 Enduro R? I ride on Mitas — previously known as E12/E13; now it’s merged and called Enduro Trail Rally Pro.
I run the Super Light version for tubes only, which is fine for me because I always ride with tubes (for my riding style).
There are also tubeless variants and the Dakar version (stiffer). I wrote a bit more about tires in another post:
What’s next?
The foundation of my adventure build is solid, but it’s definitely not the end. I still plan to do mapping, change the license plate mount, and I will definitely swap the rear spring for a stiffer one calculated specifically for my weight with luggage.
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