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17 ENGINE 111

17.3.3 Removing starter motor

300001-01

– Remove screws 1. Take off the starter motor.

17.3.4 Removing valve cover

300003-10

– Remove screws 1. Take off the valve cover with the valve cover seal.

17.3.5 Removing the alternator cover

300004-10

– Remove screws 1. Take off the alternator cover.

– Remove dowels.

17.3.6 Removing spacer

302124-10

– Remove the spacer 1 of the countershaft.

17.3.7 Removing gear position sensor

302126-10

– Remove screws. Remove the gear position sensor 1.

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Repair Manual8
- Degrees of Risk and Symbols8
- Work Rules8
3 Important Notes9
- Guarantee, Warranty9
- Operating and Auxiliary Substances9
- Spare Parts, Accessories9
- Figures9
4 Serial Numbers10
- Chassis Number10
- Type Label10
- Engine Number10
- Key Number10
- Fork Part Number10
- Shock Absorber Part Number11
5 Motorcycle12
- Raising the Motorcycle with the Lift Stand12
- Removing the Motorcycle from the Lift Stand12
- Raising the Motorcycle with the Work Stand12
- Removing the Motorcycle from the Work Stand13
- Starting13
- Starting the Motorcycle to Make Checks14
6 Fork, Triple Clamp15
- Adjusting the Compression Damping of the Fork15
- Adjusting the Rebound Damping of the Fork15
- Bleeding the Fork Legs15
- Cleaning the Dust Boots of the Fork Legs16
- Loosening the Fork Protection16
- Positioning the Fork Protection16
- Removing the Fork Legs17
- Installing the Fork Legs18
- Servicing the Fork19
- Disassembling the Fork Legs20
- Disassembling the Cartridge23
- Disassembling the Tap Compression24
- Checking the Fork Legs25
- Assembling the Tap Compression26
- Assembling the Cartridge27
- Assembling the Fork Legs29
- Checking the Steering Head Bearing Play33
- Adjusting the Play of the Steering Head Bearing33
7 Handlebar, Controls35
- Handlebar Position35
- Adjusting Handlebar Position35
- Checking the Routing of the Throttle Cable35
- Checking the Play in the Throttle Cable36
- Adjusting the Play in the Throttle Cable36
8 Frame38
- Removing the Engine Guard38
- Installing the Engine Guard38
9 Shock Absorber, Swingarm39
- Adjusting the High-Speed Compression Damping of the Shock Absorber39
- Adjusting the Low-Speed Compression Damping of the Shock Absorber39
- Adjusting the Rebound Damping of the Shock Absorber40
10 Exhaust58
- Removing the Manifold58
- Installing the Manifold58
- Removing the Main Silencer59
- Installing the Main Silencer60
11 Air Filter61
- Removing the Air Filter61
- Installing the Air Filter61
- Removing the Air Filter Box61
- Installing the Air Filter Box62
12 Fuel Tank, Seat, Trim64
- Opening the Filler Cap64
- Closing Filler Cap64
- Removing the Seat64
- Mounting the Seat65
- Taking off the Side Cover65
- Mounting the Side Cover65
- Checking the Fuel Pressure66
- Changing the Fuel Filter67
- Changing the Fuel Pump70
13 Wheels73
- Checking the Tire Air Pressure73
- Checking the Tire Condition73
- Checking the Brake Discs74
- Checking the Spoke Tension74
- Checking the Rim Run-Out75
- Front Wheel75
- Removing the Front Wheel75
- Installing the Front Wheel76
- Removing the Brake Disc of the Front Brake76
- Installing the Brake Disc of the Front Brake77
- Rear Wheel77
- Removing Rear Wheel77
- Installing the Rear Wheel77
- Removing the Brake Disc of the Rear Brake78
- Installing the Brake Disc of the Rear Brake79
- Checking the Chain Tension79
- Adjusting the Chain Tension79
- Adjusting Chain Guide80
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide80
- Cleaning the Chain82
- Checking the Rear Hub Rubber Dampers82
14 Wiring Harness, Battery84
- Removing the Battery84
- Installing the Battery84
- Disconnecting the Battery84
- Connecting the Battery85
- Recharging the Battery85
- Checking the Charging Voltage86
- Changing the Main Fuse87
- Changing Fuses of Individual Power Consumers87
- Adjusting the Engine Characteristic88
15 Brake System90
- Checking the Front Brake Linings90
- Changing the Front Brake Linings90
- Checking the Free Travel of the Hand Brake Lever92
- Adjusting the Free Travel of the Hand Brake Lever92
- Checking the Front Brake Fluid Level92
- Adding Front Brake Fluid93
- Changing the Front Brake Fluid93
- Checking the Rear Brake Linings95
- Changing the Rear Brake Linings95
- Checking the Free Travel of Foot Brake Lever96
- Adjusting the Basic Position of the Foot Brake Lever97
- Checking Rear Brake Fluid Level97
- Adding Rear Brake Fluid98
- Changing the Rear Brake Fluid98
16 Lighting System, Instruments100
- Combination Instrument100
- Setting Kilometers or Miles100
- Setting the Clock100
- Setting/Resetting Display TRIP 1100
- Setting/Resetting Display TRIP 2100
- Setting the Wheel Circumference101
- Checking the Headlight Setting102
- Adjusting the Headlight Range102
- Removing the Headlight Mask with the Headlight102
- Installing the Headlight Mask with the Headlight103
- Changing the Parking Light Bulb103
- Changing the Headlight Bulb104
- Changing the Turn Signal Bulb104
17 Engine106
- Removing the Engine106
- Installing the Engine108
- Engine Disassembly112
- Clamping the Engine into the Engine Assembly Stand112
- Draining the Engine Oil112
- Removing Starter Motor113
- Removing Valve Cover113
- Removing the Alternator Cover113
- Removing Spacer113
- Removing Gear Position Sensor113
- Removing Oil Filter114
- Removing Thermostat114
- Setting Engine to Ignition Top Dead Center114
- Removing Water Pump Wheel115
- Removing Clutch Cover115
- Removing Spacer and Spring116
- Removing Spark Plug116
- Removing Timing Chain Tensioner116
- Removing Camshafts116
- Removing Cylinder Head117
- Removing Piston117
- Removing Rotor117
- Removing Timing Chain Rails118
- Removing Timing Chain and Timing Chain Sprocket118
- Removing Crankshaft Position Sensor119
- Removing Clutch Cage119
- Removing Primary Gear120
- Removing Starter Drive120
- Removing Shift Shaft121
- Removing Shift Drum Locating121
- Removing Locking Lever121
- Removing Oil Pumps121
- Removing Left Engine Case122
- Removing Crankshaft and Balancer Shaft122
- Removing Transmission Shafts123
- Work on Individual Parts124
- Work on the Right Section of the Engine Case124
- Work on the Left Section of the Engine Case125
- Work on the Clutch Cover127
- Removing Crankshaft Bearing Inner Ring127
- Removing Balancer Shaft Drive Wheel127
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin127
- Checking Crankshaft Run-Out at Bearing Pin129
- Installing Balancer Shaft Drive Wheel129
- Installing Crankshaft Bearing Inner Ring130
- Measuring Axial Clearance of Crankshaft and Balancer Shaft130
- Cylinder - Nikasil ® Coating131
- Checking/Measuring the Cylinder131
- Checking/Measuring the Piston132
- Checking Piston Ring End Gap133
- Checking Piston/Cylinder Mounting Clearance133
- Checking Oil Pumps for Wear133
- Replacing Autodecompressor134
- Preparing Timing Chain Tensioner for Installation134
- Checking Timing Assembly135
- Removing Rocker Arm135
- Changing Camshaft Bearing136
- Removing Valves137
- Checking Valves137
- Checking Valve Springs138
- Checking Valve Spring Retainer138
- Checking Cylinder Head138
- Installing Valves139
- Installing Rocker Arm139
- Disassembling the Antihopping Clutch140
- Checking the Clutch140
  - Preassembling the Antihopping Clutch142
  - Checking Shift Mechanism143
  - Preassembling Shift Shaft143
  - Disassembling the Main Shaft144
  - Dismantling Countershaft144
  - Checking the Transmission145
  - Assembling the Main Shaft146
  - Assembling Countershaft147
  - Checking the Starter Drive148
  - Removing Freewheel148
  - Checking Freewheel149
  - Installing Freewheel149
  - Engine Assembly150
  - Installing Transmission Shafts150
  - Installing Crankshaft and Balancer Shaft151
  - Installing Left Engine Case152
  - Installing Oil Pumps152
  - Installing Locking Lever153
  - Installing Shift Drum Locating153
  - Installing Shift Shaft153
  - Installing Starter Drive153
  - Installing Primary Gear154
  - Clutch Cage, Installing154
  - Installing Crankshaft Position Sensor155
  - Installing Timing Chain and Timing Chain Sprocket156
  - Installing Timing Chain Rails156
  - Installing Rotor156
  - Adjusting Crankshaft Position Sensor Distance157
  - Setting Engine to Top Dead Center157
  - Installing Piston157
  - Installing Cylinder Head159
  - Installing Camshafts159
  - Installing Timing Chain Tensioner160
  - Checking Valve Clearance160
  - Adjusting Valve Clearance161
  - Installing Spark Plug162
  - Installing Spacer and Spring162
  - Installing Clutch Cover162
  - Mounting Water Pump Cover162
  - Installing Thermostat163
  - Installing the Oil Filter163
  - Installing Gear Position Sensor163
  - Installing the Spacer164
  - Installing Oil Screens164
  - Installing Alternator Cover165
  - Installing the Starter Motor165
  - Installing Valve Cover166
  - Removing the Engine from the Engine Assembly Stand166
18 Clutch167
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch167
- Changing the Hydraulic Clutch Fluid167
19 Water Pump, Cooling System168
- Draining the Coolant168
- Filling/Bleeding the Cooling System168
- Checking the Antifreeze and Coolant Level169
- Checking the Coolant Level170
20 Lubrication System171
- Oil Circuit171
- Checking the Engine Oil Level171
- Checking the Engine Oil Pressure172
- Changing the Engine Oil and Filter, Cleaning the Oil Screens173
- Draining the Engine Oil173
- Removing the Oil Filter174
- Installing the Oil Filter174
- Cleaning the Oil Screens175
- Filling up with Engine Oil176
- Adding Engine Oil176
21 Ignition System177
- Alternator - Checking the Stator Winding177
- Checking the Spark Plug Connector177
- Ignition Coil - Checking the Secondary Winding178
22 Technical Data179
- Engine179
- Engine Tolerance, Wear Limits179
- Engine Tightening Torques181
- Capacities182
- Engine Oil182
- Coolant182
- Fuel182
- Chassis182
- Electrical System183
- Tires183
- Fork184
- Shock Absorber184
- Chassis Tightening Torques185
23 Cleaning/Protective Treatment187
- Cleaning the Motorcycle187
- Checks and Maintenance Steps for Winter Operation188
24 Storage189
- Preparing for Use after Storage189
25 Service Schedule190
26 Wiring Diagram192
- 190192
- 192194
- 194196
- 196198
- 198200
- 200202
- 202204
- 204206
- 206208
- 208210
27 Substances212
28 Auxiliary Substances214
29 Special Tools216
30 Standards229
- Index230

Brand	KTM
Model	690 Enduro R EU 2012
Category	Motorcycle
Language	English

KTM 690 Enduro R EU 2012 User Manual

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KTM 690 Enduro R EU 2012 Specifications

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