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30/DISASSEMBLING THE ENGINE 102

300013-10

– Remove screw . Take off the water pump wheel .

– Take off the water pump cover seal.

Info

Do not lose the centering pins.

300014-10

– Remove the shaped washer .

18.12Removing clutch cover

300015-10

– Remove screws . Take off the clutch cover.

– Take off the dowels. Remove the clutch cover seal.

18.13Removing spacer and spring

300154-10

– Remove the spacer  and spring  of the shift shaft.

18.14Removing spark plug

300016-10

– Remove the spark plug using the special tool .

Spark plug wrench (75029172000) ( p. 219)

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

Brand	KTM
Model	690 ENDURO EU 2008
Category	Motorcycle
Language	English

KTM 690 ENDURO EU 2008 User Manual

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KTM 690 ENDURO EU 2008 Specifications

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