KTM 690 ENDURO EU 2008 User Manual

30/ENGINE - WORK ON INDIVIDUAL PARTS 124
19.23Checking valves
200193-10
– Check the run-out at the valve plate.
Valve - run-out
On the valve plate ≤ 0.05 mm (≤ 0.002 in)
» If the measured value does not equal the specified value:
– Change the valve.
0
0
AA
400373-10
– Check the sealing seat  on the valve.
Valve - sealing seat width
Intake 1.60 mm (0.063 in)
Valve - sealing seat width
Exhaust 2.00 mm (0.0787 in)
» If the sealing area is not in the center of the valve seat or deviates from the
specified value:
– Machine the valve seat.
19.24Checking valve springs
300118-10
– Check the valve springs for fractures and wear (visual check).
» If the valve spring is fractured or worn:
– Change the valve spring.
– Measure the valve spring lengths.
Valve spring
Minimum length (without valve
spring cap)
42.3 mm (1.665 in)
» If the measured value does not equal the specified value:
– Change the valve spring.
19.25Checking valve spring retainer
300162-10
– Check the valve spring retainer for fractures and wear (visual check).
» If the valve spring retainer is fractured or worn:
– Change the valve spring retainer.
– Measure the thickness of the valve spring retainer.
Valve spring cap - thickness 2.4… 2.5 mm (0.094… 0.098 in)
» If the measured value does not equal the specified value:
– Change the valve spring retainer.
19.26Checking cylinder head
300119-10
– Check the valve guides using the special tool .
Limit plug gauge (59029026006) ( p. 213)
» If the special tool is easy to insert into the valve guide:
– Change the valve guide and valve.
– Check the sealing area of the spark plug thread and the valve seats for damage and
tearing.
» If there is wear or tearing:
– Change the cylinder head.

KTM 690 ENDURO EU 2008 Specifications

General

Brand	KTM
Model	690 ENDURO EU 2008
Category	Motorcycle
Language	English

Summary

Front Fork and Triple Clamp Maintenance

Adjusting Front Fork Damping

Removing and Installing Fork Legs

Detailed steps for removing and installing the front fork legs.

Disassembling and Assembling Fork Components

Checking and Adjusting Steering Head Bearing Play

Rear Suspension and Swingarm Maintenance

Adjusting Shock Absorber Damping

Shock Absorber Servicing

Removing and Installing Shock Absorber

Detailed steps for removing and installing the rear shock absorber.

Front Wheel Maintenance

Front Wheel Removal and Installation

Detailed steps for removing and installing the front wheel.

Brake Disc Checks

Rear Wheel Maintenance

Rear Wheel Removal and Installation

Detailed steps for removing and installing the rear wheel.

Battery and Wiring Harness Maintenance

Battery Procedures

Adjusting Engine Characteristic

Brake System Maintenance

Front Brake System Maintenance

Procedures for front brake linings, lever, and fluid.

Rear Brake System Maintenance

Procedures for rear brake linings, lever, and fluid.

Engine Removal and Installation

Engine Removal Procedures

Detailed steps for removing the engine from the motorcycle.

Engine Installation Procedures

Detailed steps for installing the engine into the motorcycle.

Engine Disassembly Procedures

Engine Component Disassembly

Engine Work on Individual Parts

Work on Engine Case Sections

Detailed procedures for working on the right and left engine case sections.

Crankshaft and Balancer Shaft Procedures

Procedures related to crankshaft and balancer shaft inspection and replacement.

Clutch and Transmission Component Work

Engine Assembly Procedures

Transmission Shafts Assembly

Crankshaft and Balancer Shaft Installation

Procedure for installing the crankshaft and balancer shaft.

Engine Case, Oil Pumps, Locking Lever Installation

Procedures for installing engine case, oil pumps, and locking lever.

Clutch Cage, Crankshaft Sensor, Timing Chain Installation

Engine Timing and Piston Installation

Procedures for setting engine timing and installing the piston.

Cylinder Head and Camshaft Installation

Procedures for installing the cylinder head and camshafts.

Timing Chain Tensioner and Valve Clearance

Procedures for installing timing chain tensioner and adjusting valve clearance.

Lubrication System Maintenance

Oil Circuit and Engine Oil Level Check

Diagram of oil circuit and procedure for checking engine oil level.

Engine Oil Pressure Check

Procedure for checking the engine oil pressure.

Engine Oil and Filter Change

Steps for changing engine oil, filter, and cleaning oil screens.

Throttle Valve Body Settings

Checking and Adjusting Motor Drive Basic Setting

Flashing EFI/EPT Control Unit

Coding EFI/EPT Control Unit

Service Schedule

Maintenance Intervals and Tasks