KTM 690 Enduro
WORKSHOP, SERVICE, REPAIR MANUAL
KTM 690 ENDURO - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop Manual and Wiring Diagram to motorcycles KTM 690 Enduro. CONTENTS: MEANS OF REPRESENTATION IMPORTANT NOTES LOCATION OF SERIAL NUMBERS - Chassis number/type label (690 Enduro, 690 Enduro R EU, 690 Enduro R AUS/UK) - Chassis number/type label (690 Enduro R USA) - Key number - Engine number - Fork part number - Shock absorber part number MOTORCYCLE - Raising the motorcycle with the lift stand - Removing the motorcycle from the lift stand - Raising the motorcycle with the work stand - Removing the motorcycle from the work stand - Starting - Starting the motorcycle to make checks 01/FORK, TRIPLE CLAMP - Adjusting the compression damping of the fork - Adjusting the rebound damping of the fork - Bleeding the fork legs - Cleaning the dust boots of the fork legs - Loosening the fork protection - Positioning the fork protection - Removing fork legs - Installing the fork legs - Servicing the fork - Disassembling the fork legs - Disassembling the cartridge - Disassembling the tap compression - Checking the fork legs (690 Enduro) - Checking the fork legs (690 Enduro R) - Assembling the tap compression - Assembling the cartridge - Assembling the fork legs (690 Enduro) - Assembling the fork legs (690 Enduro R) - Checking the steering head bearing play - Adjusting the play of the steering head bearing 02/HANDLEBAR, INSTRUMENTS - Handlebar position - Adjusting handlebar position - Checking the play in the throttle cable - Adjusting the play in the throttle cable 03/FRAME - Removing the engine guard - Installing the engine guard 04/SHOCK ABSORBER, SWINGARM - Adjusting the high-speed compression damping of the shock absorber - Adjusting the low-speed compression damping of the shock absorber - Adjusting the rebound damping of the shock absorber - Measuring the unloaded rear wheel sag - Checking the static sag of the shock absorber - Checking the riding sag of the shock absorber - Adjusting the spring preload of the shock absorber - Adjusting the riding sag - Removing the shock absorber - Installing the shock absorber - Servicing the shock absorber - Removing the spring - Dismantling the damper - Disassembling the piston rod - Checking the damper - Removing the heim joint - Installing the heim joint - Assembling the piston rod - Assembling the damper - Bleeding and filling the damper - Filling the damper with nitrogen - Installing the spring 05/EXHAUST - Removing the exhaust manifold - Installing exhaust manifold - Removing the main silencer - Installing the main silencer 06/AIR FILTER - Removing the air filter - Installing the air filter - Removing the air filter box - Installing the air filter box 07/FUEL TANK, SEAT, TRIM - Opening filler cap - Closing filler cap - Removing the seat - Mounting the seat - Taking off the side cover - Mounting the side cover - Checking the fuel pressure - Changing the fuel filter 09/FRONT WHEEL - Removing the front wheel - Installing the front wheel - Checking the tire air pressure - Checking the tire condition - Checking the brake discs 10/REAR WHEEL - Removing rear wheel - Installing the rear wheel - Checking the chain tension - Adjusting the chain tension - Adjusting chain guide - Checking the chain, rear sprocket and engine sprocket - Cleaning the chain - Checking the rear hub rubber dampers - Checking the spoke tension - Checking the rim run-out 11/WIRING HARNESS, BATTERY - Removing the battery - Installing the battery - Disconnecting the battery - Connecting the battery - Recharging the battery - Checking the charging voltage - Changing the main fuse - Changing fuses of individual power consumers - Adjusting the engine characteristic 13/BRAKE SYSTEM - Checking the front brake linings - Changing the front brake linings - Checking the free travel of the hand brake lever - Adjusting the free travel of the hand brake lever - Checking the front brake fluid level - Adding front brake fluid - Changing the front brake fluid - Checking the rear brake linings - Changing rear brake linings - Checking the free travel of foot brake lever - Adjusting the basic position of the foot brake lever - Checking rear brake fluid level - Adding rear brake fluid - Changing the rear brake fluid 14/LIGHT SYSTEM, INSTRUMENTS - Setting kilometers or miles - Setting the clock - Combination instrument - setting/resetting TRIP 1 - Combination instrument - setting/resetting TRIP 2 - Combination instrument - setting the wheel circumference (690 Enduro) - Checking the headlight setting - Adjusting the headlight range - Removing the headlight mask with the headlight - Installing the headlight mask with the headlight - Changing the parking light bulb - Changing the headlight bulb - Changing the turn signal bulb 30/ENGINE - Removing the engine - Installing the engine 30/DISASSEMBLING THE ENGINE - Clamping engine into engine work stand - Draining the engine oil - Removing starter motor - Removing valve cover - Removing the alternator cover - Removing spacer - Removing gear position sensor - Removing oil filter - Removing thermostat - Setting engine to ignition top dead center - Removing water pump wheel - Removing clutch cover - Removing spacer and spring - Removing spark plug - Removing timing chain tensioner - Removing camshafts - Removing cylinder head - Removing piston - Removing rotor - Removing timing chain rails - Removing timing chain and timing chain sprocket - Removing crankshaft position sensor - Removing clutch cage - Removing primary gear - Removing starter drive - Removing shift shaft - Removing shift drum locating - Removing locking lever - Removing oil pumps - Removing left engine case - Removing crankshaft and balancer shaft - Removing transmission shafts 30/ENGINE - WORK ON INDIVIDUAL PARTS - Work on the right section of the engine case - Work on the left section of the engine case - Work on the clutch cover - Removing crankshaft bearing inner ring - Removing balancer shaft drive wheel - Changing the conrod bearing - Checking crankshaft run-out at bearing pin - Installing balancer shaft drive wheel - Installing crankshaft bearing inner ring - Measuring axial clearance of crankshaft and balancer shaft - Cylinder - Nikasil® coating - Checking/measuring the cylinder - Checking/measuring the piston - Checking piston ring - Checking piston/cylinder mounting clearance - Checking oil pumps for wear - Replacing autodecompressor - Preparing timing chain tensioner for installation - Checking timing assembly - Removing rocker arm - Changing camshaft bearing - Removing valves - Checking valves - Checking valve springs - Checking valve spring retainer - Checking cylinder head - Installing valves - Installing rocker arm - Dismantling antihopping clutch - Checking the clutch - Preassembling antihopping clutch - Checking shift mechanism - Preassembling shift shaft - Disassembling the main shaft - Dismantling countershaft - Checking the transmission - Assembling the main shaft - Assembling countershaft - Checking electric starter drive - Removing freewheel - Checking freewheel - Installing freewheel 30/ASSEMBLING THE ENGINE - Installing transmission shafts - Installing crankshaft and balancer shaft - Installing left engine case - Installing oil pumps - Installing locking lever - Installing shift drum locating - Installing shift shaft - Installing starter drive - Installing primary gear - Installing clutch cage - Installing crankshaft position sensor - Installing timing chain and timing chain sprocket - Installing timing chain rails - Installing rotor - Adjusting crankshaft position sensor distance - Setting engine to top dead center - Installing piston - Installing cylinder head - Installing camshafts - Installing timing chain tensioner - Checking valve clearance - Adjusting valve clearance - Installing spark plug - Installing spacer and spring - Installing clutch cover - Mounting water pump cover - Installing thermostat - Installing the oil filter - Installing gear position sensor - Installing the spacer - Installing oil screens - Installing alternator cover - Installing starter motor - Installing valve cover - Taking engine off universal mounting rack 32/CLUTCH - Checking/rectifying the fluid level of the hydraulic clutch 35/WATER PUMP, COOLING SYSTEM - Draining the coolant - Filling the cooling system - Checking the antifreeze and coolant level - Checking the coolant level 38/LUBRICATION SYSTEM - Oil circuit - Checking the engine oil level - Checking the engine oil pressure - Changing the engine oil and filter, cleaning the oil screens - Draining the engine oil - Removing the oil filter - Installing the oil filter - Cleaning the oil screens - Filling up with engine oil - Adding engine oil 39/IGNITION SYSTEM - Alternator - checking the stator winding - Checking the spark plug connector - Ignition coil - checking the secondary winding 41/THROTTLE VALVE BODY - Checking the basic setting of the motor drive - Adjusting the basic setting of the motor drive - Flashing the EFI control unit and/or the EPT control unit - Requesting the enabling code - Coding the EFI control unit and/or EPT control unit TECHNICAL DATA - ENGINE - Capacity - engine oil - Capacity - coolant TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - CHASSIS - Lighting equipment - Capacity - fuel TECHNICAL DATA - FORK - 690 Enduro - 690 Enduro R TECHNICAL DATA - SHOCK ABSORBER - 690 Enduro - 690 Enduro R TECHNICAL DATA - CHASSIS TIGHTENING TORQUES CLEANING/PROTECTIVE TREATMENT - Cleaning the motorcycle - Protective treatment for winter operation STORAGE - Storage - Putting into operation after storage SERVICE SCHEDULE - Service schedule WIRING DIAGRAM - Page 1 of 10 (690 Enduro) - Page 2 of 10 (690 Enduro) - Page 3 of 10 (690 Enduro) - Page 4 of 10 (690 Enduro) - Page 5 of 10 (690 Enduro) - Page 6 of 10 (690 Enduro) - Page 7 of 10 (690 Enduro) - Page 8 of 10 (690 Enduro) - Page 9 of 10 (690 Enduro) - Page 10 of 10 (690 Enduro) - Page 1 of 10 (690 Enduro R) - Page 2 of 10 (690 Enduro R) - Page 3 of 10 (690 Enduro R) - Page 4 of 10 (690 Enduro R) - Page 5 of 10 (690 Enduro R) - Page 6 of 10 (690 Enduro R) - Page 7 of 10 (690 Enduro R) - Page 8 of 10 (690 Enduro R) - Page 9 of 10 (690 Enduro R) - Page 10 of 10 (690 Enduro R) SUBSTANCES AUXILIARY SUBSTANCES SPECIAL TOOLS STANDARDS INDEX
KTM 690 Enduro - Workshop Manual - Wiring Diagrams
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