690 ENDURO EU 2008

KTM 690 ENDURO EU 2008 User Manual

KTM 690 ENDURO EU 2008

231 pages

To Next Page

To Next Page

Page #1 background image

Loading...

Page #1 background image

REPAIR MANUAL 2008

690 Enduro EU

690 Enduro AUS/UK

690 Enduro USA

Article no. 3206041en

Table of Contents

Table of Contents4
Means of Representation7
Important Notes8
Location of Serial Numbers9
- Chassis Number/Type Label (690 Enduro EU, 690 Enduro AUS/UK)9
- Chassis Number/Type Label (690 Enduro USA)9
- Key Number9
- Engine Number9
- Fork Part Number10
- Shock Absorber Part Number10
Motorcycle11
- Raising the Motorcycle with the Lift Stand11
- Removing the Motorcycle from the Lift Stand11
- Raising the Motorcycle with the Work Stand11
- Removing the Motorcycle from the Work Stand12
- Starting12
- Starting the Motorcycle to Make Checks13
01/Fork, Triple Clamp14
- Adjusting Compression Damping of Fork14
- Adjusting Rebound Damping of Fork14
- Bleeding the Fork Legs14
- Cleaning the Dust Boots of the Fork Legs15
- Loosening the Fork Protection15
- Positioning the Fork Protection15
- Removing Fork Legs16
- Installing the Fork Legs17
- Servicing the Fork18
- Disassembling the Fork Legs19
- Disassembling the Cartridge21
- Disassembling the Tap Compression23
- Checking the Fork Legs24
- Assembling the Tap Compression25
- Assembling the Cartridge26
- Assembling the Fork Legs27
- Checking the Steering Head Bearing Play31
- Adjusting the Play of the Steering Head Bearing31
02/Handlebar, Instruments32
- Handlebar Position32
- Adjusting Handlebar Position32
- Checking the Play in the Throttle Cable32
- Adjusting the Play in the Throttle Cable33
03/Frame34
- Removing the Engine Guard34
- Installing the Engine Guard34
04/Shock Absorber, Swingarm35
- Adjusting High-Speed Compression Damping of the Shock Absorber35
- Adjusting the Low-Speed Compression Damping of the Shock Absorber35
- Adjusting Rebound Damping of the Shock Absorber36
- Measuring the Unloaded Rear Wheel Sag36
- Checking the Static Sag of the Shock Absorber36
- Checking the Riding Sag of the Shock Absorber37
- Adjusting the Spring Preload of the Shock Absorber37
- Adjusting the Riding Sag38
- Removing the Shock Absorber38
- Installing the Shock Absorber39
- Servicing the Shock Absorber40
- Removing the Spring41
- Dismantling the Damper41
- Disassembling the Piston Rod42
- Checking the Damper43
- Removing the Heim Joint44
- Installing the Heim Joint45
- Assembling the Piston Rod46
- Assembling the Damper47
- Bleeding and Filling the Damper49
- Filling the Damper with Nitrogen51
- Installing the Spring51
05/Exhaust53
- Removing the Exhaust Manifold53
- Installing Exhaust Manifold53
- Removing the Main Silencer54
- Installing the Main Silencer55
06/Air Filter57
- Removing the Air Filter57
- Installing the Air Filter57
- Removing the Air Filter Box57
- Installing the Air Filter Box58
07/Fuel Tank, Seat, Trim60
- Opening Filler Cap60
- Closing Filler Cap60
- Removing the Seat60
- Mounting the Seat60
- Taking off the Side Cover60
- Mounting the Side Cover61
- Checking the Fuel Pressure61
- Changing the Fuel Filter62
09/Front Wheel65
- Removing the Front Wheel65
- Installing the Front Wheel65
- Checking the Tire Air Pressure66
- Checking the Tire Condition66
- Checking the Brake Discs67
10/Rear Wheel68
- Removing Rear Wheel68
- Installing the Rear Wheel68
- Checking the Chain Tension69
- Adjusting the Chain Tension69
- Adjusting Chain Guide70
- Checking the Chain, Rear Sprocket and Engine Sprocket70
- Cleaning the Chain71
- Checking the Rear Hub Rubber Dampers72
- Checking the Spoke Tension72
- Checking the Rim Run-Out73
11/Wiring Harness, Battery74
- Removing the Battery74
- Installing the Battery74
- Disconnecting the Battery74
- Connecting the Battery75
- Recharging the Battery75
- Checking the Charging Voltage76
- Changing the Main Fuse76
- Changing Fuses of Individual Power Consumers77
- Adjusting the Engine Characteristic78
13/Brake System79
- Checking the Front Brake Linings79
- Changing the Front Brake Linings79
- Checking the Free Travel of the Hand Brake Lever81
- Adjusting the Free Travel of the Hand Brake Lever81
- Checking the Front Brake Fluid Level81
- Adding Front Brake Fluid82
- Changing the Front Brake Fluid82
- Checking the Rear Brake Linings83
- Changing Rear Brake Linings84
- Checking the Free Travel of Foot Brake Lever85
- Adjusting the Basic Position of the Foot Brake Lever85
- Checking Rear Brake Fluid Level86
- Adding Rear Brake Fluid86
- Changing the Rear Brake Fluid87
14/Light System, Instruments89
- Setting Kilometers or Miles89
- Setting the Clock89
- Combination Instrument - Setting/Resetting TRIP 189
- Combination Instrument - Setting/Resetting TRIP 290
- Combination Instrument - Setting the Wheel Circumference90
- Checking the Headlight Setting91
- Adjusting the Headlight Range91
- Removing the Headlight Mask with the Headlight91
- Installing the Headlight Mask with the Headlight92
- Changing the Parking Light Bulb92
- Changing the Headlight Bulb93
- Changing the Flasher Bulb93
30/Engine95
- Removing the Engine95
- Installing the Engine97
30/Disassembling the Engine101
- Clamping Engine into Engine Work Stand101
- Draining the Engine Oil101
- Removing Starter Motor101
- Removing Valve Cover101
- Removing the Alternator Cover102
- Removing Spacer102
- Removing Gear Position Sensor102
- Removing Oil Filter102
- Removing Thermostat103
- Setting Engine to Ignition Top Dead Center103
- Removing Water Pump Wheel103
- Removing Clutch Cover104
- Removing Spacer and Spring104
- Removing Spark Plug104
- Removing Timing Chain Tensioner105
- Removing Camshafts105
- Removing Cylinder Head105
- Removing Piston105
- Removing Rotor106
- Removing Timing Chain Rails106
- Removing Timing Chain and Timing Chain Sprocket107
- Removing Crankshaft Position Sensor107
- Removing Clutch Cage107
- Removing Primary Gear109
- Removing Starter Drive109
- Removing Shift Shaft109
- Removing Shift Drum Locating109
- Removing Locking Lever110
- Removing Oil Pumps110
- Removing Left Engine Case110
- Removing Crankshaft and Balancer Shaft111
- Removing Transmission Shafts111
30/Engine - Work on Individual Parts113
- Work on the Right Section of the Engine Case113
- Work on the Left Section of the Engine Case114
- Work on the Clutch Cover115
- Removing Crankshaft Bearing Inner Ring116
- Removing Balancer Shaft Drive Wheel116
- Changing the Conrod Bearing116
- Checking Crankshaft Run-Out at Bearing Pin118
- Installing Balancer Shaft Drive Wheel118
- Installing Crankshaft Bearing Inner Ring118
- Measuring Axial Clearance of Crankshaft and Balancer Shaft119
- Cylinder - Nikasil Coating119
- Checking/Measuring the Cylinder120
- Checking/Measuring the Piston120
- Checking Piston Ring End Gap121
- Checking Piston/Cylinder Mounting Clearance122
- Checking Oil Pumps for Wear122
- Replacing Autodecompressor122
- Preparing Timing Chain Tensioner for Installation123
- Checking Timing Assembly124
- Removing Rocker Arm124
- Changing Camshaft Bearing124
- Removing Valves125
- Checking Valves126
- Checking Valve Springs126
- Checking Valve Spring Retainer126
- Checking Cylinder Head126
- Installing Valves127
- Installing Rocker Arm128
- Dismantling Antihopping Clutch128
- Checking the Clutch129
- Preassembling Antihopping Clutch130
- Checking Shift Mechanism131
- Preassembling Shift Shaft131
- Disassembling the Main Shaft132
- Dismantling Countershaft132
- Checking the Transmission133
- Assembling the Main Shaft134
- Assembling Countershaft135
- Checking Electric Starter Drive136
- Removing Freewheel136
- Checking Freewheel137
- Installing Freewheel137
30/Assembling the Engine139
- Installing Transmission Shafts139
- Installing Crankshaft and Balancer Shaft140
- Installing Left Engine Case140
- Installing Oil Pumps141
- Installing Locking Lever141
- Installing Shift Drum Locating141
- Installing Shift Shaft142
- Installing Starter Drive142
- Installing Primary Gear142
- Installing Clutch Cage143
- Installing Crankshaft Position Sensor144
- Installing Timing Chain and Timing Chain Sprocket144
- Installing Timing Chain Rails145
- Installing Rotor145
- Adjusting Crankshaft Position Sensor Distance145
- Setting Engine to Top Dead Center146
- Installing Piston146
- Installing Cylinder Head147
- Installing Camshafts148
- Installing Timing Chain Tensioner148
- Checking Valve Clearance149
- Adjusting Valve Clearance149
- Installing Spark Plug150
- Installing Spacer and Spring150
- Installing Clutch Cover150
- Mounting Water Pump Cover151
- Installing Thermostat151
- Installing the Oil Filter151
- Installing Gear Position Sensor152
- Installing the Spacer152
- Installing Oil Screens153
- Installing Alternator Cover153
- Installing Starter Motor154
- Installing Valve Cover154
- Taking Engine off Universal Mounting Rack154
32/Clutch155
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch155
35/Water Pump, Cooling System156
- Draining Coolant156
- Filling the Cooling System156
- Checking the Antifreeze and Coolant Level157
- Checking the Coolant Level158
38/Lubrication System159
- Oil Circuit159
- Checking the Engine Oil Level159
- Checking the Engine Oil Pressure160
- Changing the Engine Oil and Filter, Cleaning the Oil Screens161
- Draining Engine Oil161
- Removing the Oil Filter162
- Installing the Oil Filter162
- Cleaning the Oil Screens163
- Filling up with Engine Oil164
- Adding Engine Oil164
39/Ignition System165
- Alternator - Checking the Stator Winding165
- Checking the Spark Plug Connector165
- Ignition Coil - Checking the Secondary Winding166
41/Throttle Valve Body167
- Checking the Basic Setting of the Motor Drive167
- Adjusting the Basic Setting of the Motor Drive168
- Flashing the EFI Control Unit And/Or the EPT Control Unit171
- Requesting the Enabling Code172
- Coding the EFI Control Unit And/Or EPT Control Unit173
Technical Data - Engine175
- Capacity - Engine Oil175
- Capacity - Coolant175
Technical Data - Tolerance, Wear Limits of Engine176
Technical Data - Engine Tightening Torques178
Technical Data - Chassis180
- Lighting Equipment180
- Capacity - Fuel181
Technical Data - Fork182
Technical Data - Shock Absorber183
Technical Data - Chassis Tightening Torques184
Cleaning/Protective Treatment186
- Cleaning the Motorcycle186
- Protective Treatment for Winter Operation187
Storage188
- Putting into Operation after Storage188
Service Schedule189
Wiring Diagram190
- 188190
- 190192
- 192194
- 194196
- 196198
- 198200
- 200202
- 202204
- 204206
- 206208
Substances210
Auxiliary Substances212
Special Tools214
Standards226
Index227

Questions and Answers:

Need help?

Do you have a question about the KTM 690 ENDURO EU 2008 and is the answer not in the manual?

KTM 690 ENDURO EU 2008 Specifications

General

Brand	KTM
Model	690 ENDURO EU 2008
Category	Motorcycle
Language	English

Related product manuals

Preview: KTM 690 ENDURO EU 2009

KTM 690 ENDURO EU 2009

KTM 690 Enduro EU 2010

Preview: KTM 690 Enduro R EU 2013

KTM 690 Enduro R EU 2013

Preview: KTM 2014 690 Enduro R EU

KTM 2014 690 Enduro R EU

Preview: KTM 690 Enduro R EU 2012

KTM 690 Enduro R EU 2012

Preview: KTM 690 ENDURO EU

KTM 690 ENDURO EU

Preview: KTM 690 Enduro R EU

KTM 690 Enduro R EU

Preview: KTM 2008 690 SMC EU

KTM 2008 690 SMC EU

Preview: KTM 690 Enduro R

KTM 690 Enduro R

Preview: KTM 690 Enduro R 2021

KTM 690 Enduro R 2021

Preview: KTM 690 Enduro R 2017

KTM 690 Enduro R 2017

Preview: KTM 690 Enduro R 2019

KTM 690 Enduro R 2019