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KTM 690 Enduro AUS 2008, Repair Manual

The KTM 690 Enduro AUS 2008 Repair Manual is a comprehensive guide for maintaining and repairing this powerful off-road motorcycle. This manual provides detailed instructions and diagrams, enabling users to troubleshoot and fix issues with ease. Download it for free from manualshive.com, your go-to source for user manuals.

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CONTENTS

3

Checking the rear brake linings ....................................... 81
Changing rear brake linings ............................................ 82
Checking the free travel of foot brake lever....................... 83
Adjusting the basic position of the foot brake lever ........... 83
Checking rear brake fluid level........................................ 84
Adding rear brake fluid .................................................. 84
Changing the rear brake fluid.......................................... 85

14/LIGHT SYSTEM, INSTRUMENTS ................................... 87

Setting kilometers or miles ............................................. 87
Setting the clock ........................................................... 87
Combination instrument - setting/resetting TRIP 1............ 87
Combination instrument - setting/resetting TRIP 2............ 88
Combination instrument - setting the wheel
circumference ............................................................... 88
Checking the headlight setting........................................ 89
Adjusting the headlight range ......................................... 89
Removing the headlight mask with the headlight .............. 89
Installing the headlight mask with the headlight............... 90
Changing the parking light bulb ...................................... 90
Changing the headlight bulb........................................... 91
Changing the flasher bulb .............................................. 91

30/ENGINE....................................................................... 93

Removing the engine ..................................................... 93
Installing the engine ...................................................... 95

30/DISASSEMBLING THE ENGINE..................................... 99

Clamping engine into engine work stand .......................... 99
Draining the engine oil................................................... 99
Removing starter motor .................................................. 99
Removing valve cover..................................................... 99
Removing the alternator cover....................................... 100
Removing spacer ......................................................... 100
Removing gear position sensor ...................................... 100
Removing oil filter ....................................................... 100
Removing thermostat ................................................... 101
Setting engine to ignition top dead center...................... 101
Removing water pump wheel ........................................ 101
Removing clutch cover ................................................. 102
Removing spacer and spring ......................................... 102
Removing spark plug ................................................... 102
Removing timing chain tensioner .................................. 103
Removing camshafts.................................................... 103
Removing cylinder head ............................................... 103
Removing piston.......................................................... 103
Removing rotor............................................................ 104
Removing timing chain rails ......................................... 104
Removing timing chain and timing chain sprocket .......... 105
Removing crankshaft position sensor ............................. 105
Removing clutch cage.................................................. 105
Removing primary gear................................................. 107
Removing starter drive ................................................. 107
Removing shift shaft.................................................... 107
Removing shift drum locating ....................................... 107
Removing locking lever ................................................ 108
Removing oil pumps .................................................... 108
Removing left engine case............................................ 108
Removing crankshaft and balancer shaft........................ 109
Removing transmission shafts....................................... 109

30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 111

Work on the right section of the engine case .................. 111
Work on the left section of the engine case .................... 112
Work on the clutch cover.............................................. 113
Removing crankshaft bearing inner ring ......................... 114

Removing balancer shaft drive wheel ............................. 114
Changing the conrod bearing ........................................ 114
Checking crankshaft run-out at bearing pin .................... 116
Installing balancer shaft drive wheel.............................. 116
Installing crankshaft bearing inner ring.......................... 116
Measuring axial clearance of crankshaft and balancer
shaft .......................................................................... 117
Cylinder - Nikasil

®

coating ............................................ 117

Checking/measuring the cylinder................................... 118
Checking/measuring the piston ..................................... 118
Checking piston ring end gap........................................ 119
Checking piston/cylinder mounting clearance ................. 120
Checking oil pumps for wear......................................... 120
Replacing autodecompressor ........................................ 120
Preparing timing chain tensioner for installation ............. 121
Checking timing assembly ............................................ 122
Removing rocker arm ................................................... 122
Changing camshaft bearing .......................................... 122
Removing valves.......................................................... 123
Checking valves........................................................... 124
Checking valve springs ................................................. 124
Checking valve spring retainer ...................................... 124
Checking cylinder head ................................................ 124
Installing valves .......................................................... 125
Installing rocker arm.................................................... 126
Dismantling antihopping clutch .................................... 126
Checking the clutch..................................................... 127
Preassembling antihopping clutch................................. 128
Checking shift mechanism ........................................... 129
Preassembling shift shaft ............................................. 129
Disassembling the main shaft ....................................... 130
Dismantling countershaft ............................................. 130
Checking the transmission............................................ 131
Assembling the main shaft ........................................... 132
Assembling countershaft .............................................. 133
Checking electric starter drive....................................... 134
Removing freewheel..................................................... 134
Checking freewheel...................................................... 135
Installing freewheel ..................................................... 135

30/ASSEMBLING THE ENGINE ........................................ 137

Installing transmission shafts ....................................... 137
Installing crankshaft and balancer shaft......................... 138
Installing left engine case ............................................ 138
Installing oil pumps ..................................................... 139
Installing locking lever ................................................. 139
Installing shift drum locating ........................................ 139
Installing shift shaft..................................................... 140
Installing starter drive .................................................. 140
Installing primary gear ................................................. 140
Installing clutch cage................................................... 141
Installing crankshaft position sensor.............................. 142
Installing timing chain and timing chain sprocket........... 142
Installing timing chain rails .......................................... 143
Installing rotor............................................................. 143
Adjusting crankshaft position sensor distance................. 143
Setting engine to top dead center.................................. 144
Installing piston .......................................................... 144
Installing cylinder head................................................ 145
Installing camshafts .................................................... 146
Installing timing chain tensioner ................................... 146
Checking valve clearance ............................................. 147
Adjusting valve clearance ............................................. 147

Summary of Contents for 690 Enduro AUS 2008

Page 1: ...REPAIR MANUAL 2008 690 Enduro EU 690 Enduro AUS UK 690 Enduro USA Article no 3206041en ...

Page 2: ......

Page 3: ...o modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The...

Page 4: ...ag 36 Removing the shock absorber 36 Installing the shock absorber 37 Servicing the shock absorber 38 Removing the spring 39 Dismantling the damper 39 Disassembling the piston rod 40 Checking the damper 41 Removing the heim joint 42 Installing the heim joint 43 Assembling the piston rod 44 Assembling the damper 45 Bleeding and filling the damper 47 Filling the damper with nitrogen 49 Installing th...

Page 5: ...111 Work on the left section of the engine case 112 Work on the clutch cover 113 Removing crankshaft bearing inner ring 114 Removing balancer shaft drive wheel 114 Changing the conrod bearing 114 Checking crankshaft run out at bearing pin 116 Installing balancer shaft drive wheel 116 Installing crankshaft bearing inner ring 116 Measuring axial clearance of crankshaft and balancer shaft 117 Cylinde...

Page 6: ...checking the stator winding 163 Checking the spark plug connector 163 Ignition coil checking the secondary winding 164 41 THROTTLE VALVE BODY 165 Checking the basic setting of the motor drive 165 Adjusting the basic setting of the motor drive 166 Flashing the EFI control unit and or the EPT control unit 169 Requesting the enabling code 170 Coding the EFI control unit and or EPT control unit 171 TE...

Page 7: ...e information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Identifies a voltage measurement Identifies a current measurement Identifies a resistance measurement Formats used The typographical and other formats used are explained in the following Name Indicates a proprietary name Protected name Identifies a protected name T...

Page 8: ...ts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Following repairs or servicing the vehicle must be checked for roadworthiness Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are miss...

Page 9: ...e chassis number is stamped on the right of the steering head The USA type label is on the right of the frame behind the steering head 700218 01 The Canada type label is on the right of the frame behind the steering head 3 3 Key number 100179 10 The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 3 4 Engine number 10...

Page 10: ...L NUMBERS 8 3 5 Fork part number 800072 10 The fork part number is stamped on the inner side of the fork stub 3 6 Shock absorber part number 100216 10 The shock absorber part number is on the right of the shock absorber ...

Page 11: ...and Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Remove the motorcycle from the lift stand and rest it on its side stand Remove the lift stand 4 3 Raising the motorcycle with the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 300579 10 Mount...

Page 12: ...stem Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds B00...

Page 13: ...stand is folded out and you shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go 4 6 Starting the motorcycle to make checks Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient vent...

Page 14: ...o Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Mount protection covers 5 2 Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork suspension behavior 100244 10 Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Tur...

Page 15: ...nd grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 211 Press the dust boots back into their normal position Remove excess oil Position the fork protection p 13 Remove the motorcycle from the lift stand p 9 5 5 Loosening the fork protection 800075 10 Remove screws and take off clamp Remove screws on lef...

Page 16: ...w about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake disc is not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 201334 10 Remove screws Take the brake li...

Page 17: ...bleeder screws must face forwards The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp The upper fork projection must be the same on both sides Tighten screws on both sides Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 201335 11 Position the wheel speed sensor Mount and tighten screws Guideline Scr...

Page 18: ...eck that the brake linings are seated correctly Mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Unload the rear of the vehicle Remove the motorcycle from the lift stand p 9 201333 11 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 5 9 Servicing the ...

Page 19: ... of the rebound and compression damping 200643 10 Clamp the fork leg in the area of the lower triple clamp Clamping stand T1403S p 222 200644 12 Loosen the screw cover Info The screw cover cannot be removed yet 200690 10 Release the fork leg and clamp it with the fork stub Info Use soft jaws 200646 12 Push the outer tube downward Pull the spring downward Mount the special tool on the hexagon Open ...

Page 20: ...e 200649 01 Pull the spring downward Remove the special tool Remove the spring 200650 01 Empty the fork oil Info Pull out and push in the piston rod a few times to empty the cartridge 200691 10 Clamp the fork leg with the fork stub Loosen and remove the tap compression Info Place a container underneath to catch any oil that may run out 200653 01 Remove the cartridge ...

Page 21: ...m the inner tube with a jerk Info The lower sliding bushing must be pulled from its bearing seat 200658 01 Remove the upper sliding bushing Info Without using a tool carefully pull the stack apart by hand 200659 11 Take off the lower sliding bushing Take off support ring Take off seal ring Take off lock ring Take off dust boot Unclamp the fork leg 5 11 Disassembling the cartridge Info These operat...

Page 22: ...eeve 200695 10 Pull piston rod out of cartridge Clamp the piston rod Remove fluid barrier Clamping stand T14016S p 222 200696 10 Take screw sleeve off of the cartridge along with the washer and spring seat 200697 10 Degrease the piston rod Clamp the piston rod with the special tool Clamping stand T14016S p 222 200698 10 Remove nut Completely remove shim stack ...

Page 23: ...pring Remove valve of the rebound damping with the spring Unclamp the piston rod 5 12 Disassembling the tap compression Info These operations are the same on both fork legs Disassemble the fork legs p 17 200702 10 Clamp the tap compression in a vise using soft jaws Remove nut Remove the spring Remove washer 200703 10 Remove piston Remove shim stack ...

Page 24: ...200684 10 Measure the external diameter of the inner tube in several places External diameter of inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Replace the inner tube 200685 10 Measure the run out of the inner tube Run out of inner tube 0 20 mm 0 0079 in If the measured value is greater than the specified value Replace the inner tube 200632 10...

Page 25: ...he tap compression Info These operations are the same on both fork legs 200704 11 Clamp the tap compression in a vise using soft jaws Mount O ring and seal ring Lubricate the O ring Lubricant T158 p 210 200705 10 Mount shim stack Info Mount with the smaller shims facing downward Mount piston with the O ring Info The side with the larger inside diameter faces upward Lubricate the O ring of the pist...

Page 26: ...701 Position spring 200719 10 Mount shim stack Info Mount with the smaller shims facing downward Press the shim stack down against the spring force Info The shim stack must be pressed down over the collar Mount piston with the piston ring Info The side with the larger inside diameter should face downward 200720 10 Mount shim stack Info Precisely align the triangular plates with the opening of the ...

Page 27: ...sembling the fork legs Info These operations are the same on both fork legs Check the fork legs p 22 Assemble the cartridge p 24 Assemble the tap compression p 23 200669 10 Clamp the inner tube with the axle clamp Mount the special tool Protecting sleeve T1401 p 221 Grease and push on dust boot Lubricant T511 p 210 Info Always replace the dust boot the seal ring the lock ring and the support ring ...

Page 28: ...3 10 Push on the outer tube Heat up the outer tube in area of the lower sliding bushings Guideline 50 C 122 F Hold the lower sliding bushing with the longer side of the special tool Assembly tool T1402S p 222 Press on the outer tube as far as it will go 200724 10 Position the support ring Hold the seal ring with the shorter side of the special tool Assembly tool T1402S p 222 Press on the outer tub...

Page 29: ...ng the piston rod 200726 10 Slide the cartridge into the inner tube Mount and tighten tap compression Guideline Tap compression M29x1 35 Nm 25 8 lbf ft Info If the cartridge itself turns press the piston rod slightly to one side 200677 10 Clamp the fork vertically Fill it with fork oil Fork oil per fork leg 645 ml 21 81 fl oz Fork oil SAE 5 p 209 Info Pull out and push in the piston rod completely...

Page 30: ...ft 200646 11 Release the special tool Pull the spring downward and take off the special tool 200681 10 Push the outer tube upward Clamp the outer tube in the area of the lower triple clamp Clamping stand T1403S p 222 Grease the O ring of the screw cover Lubricant T158 p 210 Screw on and tighten the screw cover Guideline Screw cover on outer tube M51x1 5 50 Nm 36 9 lbf ft 200727 10 Alternative 1 Tu...

Page 31: ...e the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the play of the steering head bearing p 29 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locatio...

Page 32: ...t M10 40 Nm 29 5 lbf ft Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Fit and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Loctite 243 6 3 Checking the play in the throttle cable 400192 10 Move the handlebar to the straight ahead position...

Page 33: ...throttle cable 100280 10 Move the handlebar to the straight ahead position Use the KTM diagnostics tool to set the motor drive to the basic position Loosen counter nut Set the play in the throttle cable by turning the adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten counter nut ...

Page 34: ...100198 10 Remove screws on the left and right Pull the engine guard forward out of the holders and set it down 7 2 Installing the engine guard 100199 10 Slide the engine guard into holders at the rear Position the engine guard Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 35: ...turn Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 8 2 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info The low speed setting can be seen during the slow to norma...

Page 36: ...n damping 8 4 Measuring the unloaded rear wheel sag Raise the motorcycle with the lift stand p 9 0 0 A A 400988 10 Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover Note down the value as dimension Remove the motorcycle from the lift stand p 9 8 5 Checking the static sag of the shock absorber 0 0 A A 0 0 B B 400989 10 Measure distance of rear...

Page 37: ...ag p 36 8 7 Adjusting the spring preload of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove the shock absorber p 36 After removing the ...

Page 38: ...rd 80 N mm 457 lb in Hard 85 N mm 485 lb in Info The spring rate is shown on the outside of the spring Install the shock absorber p 37 Check the static sag of the shock absorber p 34 Adjust the rebound damping of the shock absorber p 34 8 9 Removing the shock absorber Raise the motorcycle with the work stand p 9 300562 10 Remove screws 300563 10 Lift the rear fairing Remove screws 300564 10 Remove...

Page 39: ... and remove 8 10 Installing the shock absorber 300566 11 Swing the rear end upwards and insert shock absorber from above 300565 11 Mount screw but do not tighten yet Mount and tighten screw Guideline Screw bottom shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Tighten screw Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 ...

Page 40: ...lbf ft Mount the side cover p 59 Remove the motorcycle from the work stand p 10 8 11 Servicing the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Condition The shock absorber has been removed 201239 01 Remove the spring p 39 Dismantle the damper p 39 Disassemble...

Page 41: ...ning ring and adjusting ring until the spring is fully relieved of ten sion 300581 10 Press down the spring with the special tool Spring compressor T101S p 220 Remove spring retainer 300582 10 Take off spring with the retaining ring and adjusting ring 8 13 Dismantling the damper Remove the spring p 39 300583 10 Establish and note the current state of the rebound damping and compression damping Com...

Page 42: ...ain the oil 300587 10 Remove the piston rod Drain the remaining oil 300588 10 Remove compression damping adjuster Remove the spring sleeve and piston 300589 10 Push back membrane cover Remove lock ring Remove membrane 8 14 Disassembling the piston rod Dismantle the damper p 39 300540 10 Clamp the piston rod with the heim joint in a vise Remove nut ...

Page 43: ... set the parts down together 300542 10 Remove seal ring retainer 300543 10 Remove locking cap and rubber buffer 8 15 Checking the damper Condition The damper has been disassembled 300596 10 Measure the inside diameter at both ends and in the center of the damper car tridge Damper cartridge Minimum diameter 46 10 mm 1 815 in If the measured value is greater than the specified value Change the dampe...

Page 44: ...od Check the piston rod for damage and wear If there is damage or wear Change the piston rod 300460 01 Check the heim joint for damage and wear If there is damage or wear Change the heim joint 8 16 Removing the heim joint Condition The shock absorber has been removed 200577 10 Clamp the shock absorber in the vise using soft jaws for protection Remove collar bushing of the heim joint Pin T120 p 220...

Page 45: ...207S p 221 8 17 Installing the heim joint 200581 10 Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool T1206 p 221 Pressing tool T129 p 221 200579 11 Mount lock rings on both sides 200578 11 Mount seal rings on both sides and grease them Lubricant T158 p 210 200582 10 Press in both collar sleeves of the heim joint ...

Page 46: ...bricant T625 p 211 Remove the special tool 200572 11 Mount supporting plate with the rounded side facing downward Mount the compression shim stack with the smaller shims facing downward 300547 10 Sand both sides of the piston on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Info The piston is the same on both sides 300541 11 Mount the rebound shim stack with the sm...

Page 47: ...amping adjustment M26x1 30 Nm 22 1 lbf ft 300586 11 Mount and tighten screw Guideline Filling port screw M10x1 14 Nm 10 3 lbf ft 300592 10 Fill the damper cartridge about half full Shock absorber oil SAE 2 5 50180342S1 p 209 300593 10 Grease O ring of the seal ring retainer Lubricant T158 p 210 Mount the piston rod carefully 300585 11 Mount seal ring retainer and push it under the ring groove Moun...

Page 48: ... speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Alternative 2 Warning Danger of accidents Modifications to the susp...

Page 49: ... filling the piston rod slides in and out do not prevent it from mov ing by holding it 200271 10 Place the control lever as shown in the photo The External tank control lever is on Closed Damper on Vacuum and Oil reservoir on Vacuum Operate the On Off switch The vacuum pump process starts Pressure gauge falls to the specified value 0 bar Vacuum gauge falls to the specified value 8 mbar 200267 10 W...

Page 50: ...mbar The pressure gauge falls to the specified value 0 bar 200268 10 When the pressure gauge reaches the specified value turn the Damper control lever to Pressure Guideline 0 bar Oil is pumped into the damper The pressure gauge rises to the specified value 3 bar 200269 10 When the pressure gauge reaches the specified value turn the Damper control lever to Vacuum Guideline 3 bar The pressure gauge ...

Page 51: ...5 psi 300599 10 Open valve Fill the damper for at least 15 seconds Guideline Gas pressure 10 bar 145 psi Info Watch the pressure regulator dial Make sure that the damper is filled to the specified pressure Close the valve Close the filling cylinder Remove the special tool Filling adapter T1516 p 223 Install the cap 8 22 Installing the spring 300580 11 Clamp the damper in the vise using soft jaws I...

Page 52: ...20 Hook wrench T157S p 223 Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components Only make adjustments within the recommended range After making adjustments ride sl...

Page 53: ...ot touch hot components Remove the air filter box p 55 300210 10 Unplug connector of the lambda sensor Open the cable binder 300207 10 Remove screws Remove the heat shield 300208 10 Remove nuts of the manifold Info Do not misplace the spacers 300209 10 Loosen screw Remove the manifold 9 2 Installing exhaust manifold 300209 11 Position the manifold at the rear with the seals ...

Page 54: ... lbf ft Copper paste 300210 11 Plug in the connector of the lambda sensor Secure the cable with the cable binders 300207 11 Position the heat shield Mount and tighten screws Guideline Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Install the air filter box p 56 9 3 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system...

Page 55: ...02047 11 Position the main silencer Mount and tighten screws Guideline Screw main silencer holder M8 25 Nm 18 4 lbf ft 302045 10 Position the exhaust clamp Tighten screw Guideline Screw exhaust clamp on manifold M8 25 Nm 18 4 lbf ft Copper paste 302044 11 Position the exhaust heat shield Mount and tighten screws Guideline Screw exhaust heat shield M5 8 Nm 5 9 lbf ft ...

Page 56: ...05 EXHAUST 54 302046 11 Mount and tighten screws Guideline Rear fairing screw M5 2 Nm 1 5 lbf ft ...

Page 57: ...he air filter box Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing surface If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Hook filter box top into the front of the air filter box and swing down 100285 11 Mount and tighten screws Guideline Screw air filter box top M6 2 Nm 1 5 lbf ft M...

Page 58: ...r spring loaded band type clamp 60029057100 p 214 Detach connector of the intake air temperature sensor Take off the air filter box 10 4 Installing the air filter box 300206 11 Attach connector of the intake air temperature sensor Mount bleed hose Mount the spring loaded band type clamp using the special tool Pliers for spring loaded band type clamp 60029057100 p 214 300205 11 Position the air fil...

Page 59: ... Nm 7 4 lbf ft 300203 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300202 11 Position the voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Route and mount vent hose without kinking Mount the side cover p 59 ...

Page 60: ...ng the seat 100230 10 Pull on strap and raise the rear of the seat at the same time Pull back the seat and lift it off 11 4 Mounting the seat 100276 10 Hook slot of the seat onto screw press the rear downward and at the same time push it forward Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click Finally check that the se...

Page 61: ...ets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Condition The fuel tank is completely full The ignition is off The di...

Page 62: ...highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoi...

Page 63: ...e screw Repeat the operation on the opposite side Swing the rear end upwards and secure it 302607 10 Remove screws Pull out the fuel pump 302608 10 Remove hose clamps Remove fuel filter 302609 10 Press lock Remove fuel pump housing 302610 10 Change fuel screen Mount the fuel pump housing ...

Page 64: ... pump M5 6 Nm 4 4 lbf ft 300564 10 Position the rear end Mount and tighten screw Guideline Screw fuel tank bottom M8 20 Nm 14 8 lbf ft Repeat the operation on the opposite side 300563 10 Lift the rear fairing Mount and tighten screws Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft Loctite 243 300562 10 Mount and tighten screws Guideline Screw side cover M5 2 Nm 1 5 lbf ft Di...

Page 65: ...s removed Always lay the wheel down in such a way that the brake disc is not dam aged 800080 10 Remove distance bushings 12 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 800080 11 Check the wheel bearing for damage and wea...

Page 66: ...ressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 12 4 Checking the tire condition Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire For your own safety have damaged tires changed immediately Warning Danger of crashing Poor vehicle handlin...

Page 67: ... The first two digits refer to the week of manufacture and last two digits refer to the year of manufac ture KTM recommends that the tires are changed regardless of the actual wear at the latest after five years If a tire is more than five years old Change the tires 12 5 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake d...

Page 68: ... Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Check the rear hub rubber dampers p 70 100269 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing Remove bushing Clean and grease the working surfaces of the bushing and sh...

Page 69: ...ean the motorcycle on the side stand Shift gear to neutral Push the chain upward at a distance from the chain sliding guard and determine the chain tension Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 5 mm 0 2 in Distance to chain sliding guard 30 mm 1 18 in If the chain tension does not mee...

Page 70: ...djustment range of the chain adjusters 30 mm 1 18 in enables different secondary transmissions with the same chain length The chain adjusters can be turned through 180 13 5 Adjusting chain guide 100299 10 Remove screws and Take off the chain guide Condition Number of teeth 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm ...

Page 71: ...iding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 302112 10 Check the chain guide for wear If the chain guide is worn Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 13 7 C...

Page 72: ...rocket facing upwards and insert the wheel spindle in the hub To check play hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If play is larger than the specified value Change all rubber dampers in the rear hub Install the rear wheel p 66 13 9 Checking the spoke tension Warning Dange...

Page 73: ...es are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400998 01 Check the axial run out and radial run out of the rim Axial run out outside of the rim joint 1 8 mm 0 071 in Radial run out outside of the rim joint 1 8 mm 0 071 in If the measured value is greater than the specified value Center the rim Info Center the rim by tightening...

Page 74: ...tive plus cable of the battery Push the wiring harness to the side and pull the battery out of the battery rack Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehicle is therefore no longer roadworthy 14 2 Installing the battery 100277 11 Slide the battery into the battery rack Info The batt...

Page 75: ...our KTM dealer or to a recycling center that accepts used batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Even when there is no load on the battery it still loses power steadily The charge state and the type of charge are very important for the ...

Page 76: ...d Remove the seat p 58 302035 10 Remove screws Push the retaining bracket forward and take off the terminal cover Start the motorcycle to make checks p 11 601014 10 Measure the voltage between the specified points Measuring point Plus Measuring point Ground Charging voltage 5 000 rpm 13 5 15 0 V If the displayed value is less than the specified value Check the plug in connections from the alternat...

Page 77: ...individual power consumers is located under the seat Switch off all power consumers and switch off the engine Remove the seat p 58 600604 11 Open fuse box cover 600606 10 Remove the defective fuse Guideline Fuse 1 10A ignition combination instrument Fuse 2 10A clock ignition EFI control unit Fuse 3 10A throttle valve control unit Fuse 4 10A fuel pump Fuse 5 10A radiator fan Fuse 6 10A horn brake l...

Page 78: ... Map Select switch out of the holder 100238 10 Turn the adjusting wheel until the desired digit is next to marking Set the Map Select switch to Soft Set the adjusting wheel to position 1 Soft reduced homologated peak performance for better driveability Set the Map Select switch to Advanced Set the adjusting wheel to position 2 Advanced homologated performance with extremely direct responsive ness ...

Page 79: ...ysician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accid...

Page 80: ... safety clip knock the pin out to the right and remove the brake linings Clean brake caliper and brake caliper support 400418 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly 800077 10 Insert the brake pads insert the bolt and mount the split pin Operate the hand brake lever repeatedly until the brake linings lie on the brake disc a...

Page 81: ...wise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make adjustments while riding 15 5 Checking the front brake fluid level Warning Danger of accidents Fai...

Page 82: ...ontact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100254 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to level Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 208 Position the cover with the membrane Mount and tight...

Page 83: ...Level 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 208 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 15 8 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Note Danger of accidents Reduced braking efficiency caus...

Page 84: ...ke linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Hazardous substances cause environmental damage ...

Page 85: ...ke circuit The rear brake can fail due to overheating Adjust free travel on foot brake lever according to specifications 100256 10 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Info You will know that contact has been made with the foot brake cylinder...

Page 86: ...nts Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule 100258 10 Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid p 84 15 13 Adding rear brake fluid Warning Danger of accidents Failure of the brake system If the brake f...

Page 87: ...gles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals an...

Page 88: ...d to the MAX mark Brake fluid DOT 4 DOT 5 1 p 208 Mount the screw cap with the washer and membrane Activate the foot brake lever until there is a firm pressure point Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 89: ...UK 690 Enduro USA Press the MODE button repeatedly until the ODO mode is active Keep the MODE button and the SET button pressed simultaneously The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simultaneously The time is set 16 3 Combination instrument setting resetting TRIP 1 Info The TRIP 1...

Page 90: ...mer in writing that these modifications are performed at the customer s own risk and that the vehicle will no longer be approved for use on public roads once modified Condition The motorcycle is stationary Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 89 302064 10 Unplug connector ED from the combination instrument Unlock pin 18 and remove ...

Page 91: ...the boundary between light and dark does not meet specifications Adjust the headlight range p 89 16 7 Adjusting the headlight range Check the headlight setting p 89 800084 10 Turn adjusting screw to adjust the headlight range Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark made in Checking headlight adjustment Info Turn clockwise to increase the head...

Page 92: ...up to the steering head 700543 01 Position groove on counterpiece 100296 10 Position brake hose guide Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 16 10 Changing the parking light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before moun...

Page 93: ...into the headlight housing Headlight H4 socket P43t p 178 Fix the headlight bulb in the headlight using the spring bar Replace the rubber cap Attach the connector Install the headlight mask with the headlight p 90 16 12 Changing the flasher bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it ...

Page 94: ...T SYSTEM INSTRUMENTS 92 Mount the orange plug Position the diffuser Insert the screw and turn it first anticlockwise until it engages in the thread Tighten the screw slightly Check the flasher system function ...

Page 95: ...ake off the shift lever 300214 10 Have an assistant operate the rear brake Bend up the lock washer Remove the nut of the engine sprocket with the lock washer Remove screws 300215 10 Remove nut Remove the chain adjuster Pull out the wheel spindle only far enough to allow the rear wheel to be pushed for ward Push the rear wheel forward as far as possible and take the chain off the rear sprocket Info...

Page 96: ...ctions of the gear position sensor the crankshaft posi tion sensor and the alternator Remove the cable binders and release the cables 300188 10 Pull of the spark plug connector Unplug the connector of the engine coolant temperature sensor 300220 10 Loosen the spring loaded band type clamp from the breather SLS and oil return line with the special tool Pliers for spring loaded band type clamp 60029...

Page 97: ...ve the swingarm pivot 300224 10 Lower the engine Info You should have an assistant for this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments from damage 17 2 Installing the engine Raise the engine onto the special tool and fix it Floor jack attachment 75029055000 p 218 300225 11 Position the engine in the frame Mount swingarm pivot Mount...

Page 98: ...uideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Tighten the swingarm pivot Guideline Screw swingarm pivot M12x1 75 80 Nm 59 lbf ft Tighten the lower engine bracket Guideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 300220 11 Position the hoses of the engine breather the SLS and the oil return line Mount the spring loaded band type clamp using the special tool Pliers...

Page 99: ...h rod Position the clutch slave cylinder Mount and tighten screws Guideline Screw clutch slave cylin der M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylin der M6x35 10 Nm 7 4 lbf ft Mount the engine sprocket with the chain Position the new lock washer and mount nut but do not tighten yet 300215 11 Position the rear wheel Mount the chain adjuster and nut Push the rear wheel forward so tha...

Page 100: ...radiator hoses Install the spring loaded band type clamps Install the exhaust manifold p 51 Disconnect the battery p 73 300802 10 Remove the oil filler plug with O ring from the clutch cover and fill up with engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 208 Alternative engine oil Engine oil SAE 10W 50 p 208 Install and tighten the oil filler plug with O ring Fill the cool...

Page 101: ...ine on special tool Info Have an assistant help you or use a crane 18 2 Draining the engine oil 300002 10 Remove the oil drain plug with the magnet and seal ring Remove plug with oil screen and the O rings 300161 10 Remove plug with oil screen and the O rings Completely drain the engine oil 18 3 Removing starter motor 300001 01 Remove screws Take off the starter motor 18 4 Removing valve cover 300...

Page 102: ...he spacer of the countershaft 18 7 Removing gear position sensor 302126 10 Remove screws Remove the gear position sensor 300007 10 Remove O ring Remove contact pin and the contact springs 18 8 Removing oil filter 300009 10 Remove screws Remove the oil filter cover with the O ring Pull the oil filter element out of the oil filter case Circlip pliers reverse 51012011000 p 212 ...

Page 103: ... radiator hose Pull out the thermostat 18 10 Setting engine to ignition top dead center 300023 10 Turn the crankshaft counterclockwise until markings of the camshafts are flush with the marks of the camshaft support plate 300024 10 Remove screw Info Look through the hole to check that the position hole of the balancer shaft is visible Screw in special tool Engine blocking screw 77329010000 p 219 1...

Page 104: ... 10 Remove the shaped washer 18 12 Removing clutch cover 300015 10 Remove screws Take off the clutch cover Take off the dowels Remove the clutch cover seal 18 13 Removing spacer and spring 300154 10 Remove the spacer and spring of the shift shaft 18 14 Removing spark plug 300016 10 Remove the spark plug using the special tool Spark plug wrench 75029172000 p 219 ...

Page 105: ...camshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft 18 17 Removing cylinder head 300029 10 Remove screws Alternately loosen screws and remove them Take off the cylinder head 18 18 Removing piston 300030 10 Take off the cylinder head gasket Remove screw Push the cylinder upward Info Push the cylinder upward only far enough to allow removal of the piston...

Page 106: ... the special tool to hold the rotor tight Holding spanner 75029091000 p 219 Loosen the nut of the rotor and remove it with the tab washer Info The crankshaft must not be blocked 302120 10 Install the special tool on the rotor Hold it tight using the special tool and pull off the rotor by turning the screw in Extractor 58429009000 p 212 Remove the special tool 18 20 Removing timing chain rails 3000...

Page 107: ...the timing chain Info Mark the direction of travel Take off the lock ring 300149 10 Pull of the timing chain sprocket with the special tool Extractor 59029033000 p 213 18 22 Removing crankshaft position sensor 300151 10 Remove the screws of crankshaft position sensor Pull cable support sleeve out of the engine case Take off the crankshaft posi tion sensor 18 23 Removing clutch cage 300051 10 Compr...

Page 108: ... up the lock washer 300054 10 Hold the clutch cage using the special tool and remove the nut of the inner clutch hub Gear segment 75029081000 p 218 Info Make sure that the crankshaft is not blocked Remove the nut of the primary gear Info Left handed thread 302125 10 Take off the stepped washer and remove the half washers Take off the clutch cage 300056 10 Remove needle bearing and supporting plate...

Page 109: ... 10 Remove the lock ring of the starter idler gear and the torque limiter Take off the starter idler gear with the washers Remove the torque limiter with the washers and needle bearing 300065 10 Take off the free wheel gear Remove the woodruff key and both needle bearings 18 26 Removing shift shaft 300066 10 Push sliding plate away from the shift drum locating Remove shift shaft with the washer 18...

Page 110: ...nd normal washers from both oil pumps Take off the oil pump toothed wheels 300071 10 Remove the pins and washers Remove screws Take off the oil pump cover 300072 10 Remove both oil pump shafts with internal rotors Take the external rotors out of the engine case 18 30 Removing left engine case 300075 10 Remove screws Swing the left engine case up and remove the nut or screw of the engine holder ...

Page 111: ...ne case The balancer shaft and the main shaft have a stop disk these usually stick to the bearing Take off the left section of the engine case Remove the special tool 300077 10 Remove dowels Remove O ring 18 31 Removing crankshaft and balancer shaft 300078 10 Remove the crankshaft and the balancer shaft 18 32 Removing transmission shafts 300079 10 Remove the shift rail 300080 10 Swing shift forks ...

Page 112: ... Ensure that the pins remain in place 300082 10 Remove the lock ring and the stop disk 300083 10 Pull both transmission shafts out of the bearing seats together Info The stop disk of the countershaft usually sticks to the bearing Take the O ring off the countershaft ...

Page 113: ...in the shaft seal rings of the water pump with the open side facing out so that it is flush Warm the engine case section again Guideline 150 C 302 F 300096 10 Insert the new cold bearings into the bearing seats of the hot engine case section and if necessary use a suitable press drift to push the bearing from the inside to the outside all the way to the stop or so it is flush Info The shift shaft ...

Page 114: ... spring with the piston valve out of the drill hole Remove any sealing mass remnants and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 150 C 302 F Knock the engine case section against a level wooden plate This will cause the bearings to drop out of the bearing seats Info Any bearings that remain in the engine case section must be removed using a suitab...

Page 115: ...n If the measured value does not equal the specified value Change the spring Check the piston valve for damage and wear If there is damage or wear Replace the piston valve 300093 10 Lubricate the piston valve and mount it with the pressure spring Mount and tighten plug with the new seal ring Guideline Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Position the membrane support plate w...

Page 116: ...balancer shaft drive wheel Remove the crankshaft bearing inner ring p 114 300133 10 Screw in 2 M6 screws in the threads Tighten the two screws evenly to pull the drive wheel off the crankshaft 19 6 Changing the conrod bearing Remove the drive wheel of the balancer shaft p 114 300137 10 Position the crankshaft with the special tool in the press Under part pressing out tool 75029047051 p 217 Positio...

Page 117: ...d the bearing Position the second crankweb 300139 10 Position the special tool with the heel at the bottom Pressing device for crankshaft complete 75029047000 p 217 Press the upper crankweb in as far as possible Info The press mandrel must be applied above the crank pin Take the crankshaft out of the special tool and check the connecting rod for free dom of movement 300143 10 Measure the axial cle...

Page 118: ...e 100 C 212 F 300159 10 Place the drive wheel on the crankshaft The dowel of the crankshaft must fit in the drill hole The side of the drive wheel with the punch mark must be visible after assembly and the side with the bevel must be in contact with the crankweb Install the crankshaft bearing inner ring p 116 19 9 Installing crankshaft bearing inner ring 300134 10 Fix the crankshaft with special t...

Page 119: ...s too large add compensation shims Install the crankshaft bearing inner ring p 116 300164 10 Mount the dial gauge support on the engine case and measure and note the axial clearance of the balancer shaft Guideline Balancer shaft axial clearance 0 05 0 20 mm 0 002 0 0079 in If the measured value does not equal the specified value Remove the balancer shaft Calculate the thickness of the compensation...

Page 120: ...e of the cylinder 400376 10 Check the sealing area of the cylinder head for distortion using a straight edge and the special tool Feeler gauge 59029041100 p 214 Cylinder cylinder head sealing area distortion 0 10 mm 0 0039 in If the measured value does not equal the specified value Change the cylinder 19 13 Checking measuring the piston 0 0 A A 0 0 A A 0 0 A A 400484 10 Use the special tool to mea...

Page 121: ...kirt at right angles to the piston pin at a dis tance Guideline Distance 31 5 mm 1 24 in Piston diameter Size I 101 955 101 965 mm 4 01397 4 01436 in Size II 101 965 101 975 mm 4 01436 4 01476 in Info Piston size is marked on the piston head 19 14 Checking piston ring end gap 300098 10 Remove the piston ring from the piston Place the piston ring in the cylinder and align it with the piston Guideli...

Page 122: ...e suction pump but it applies to all oil pumps 300106 10 Use a feeler gauge to measure the play between the external rotor and the engine case as well as between the external rotor and the internal rotor Oil pump Clearance between external rotor and engine case 0 20 mm 0 0079 in Clearance between external rotor and internal rotor 0 20 mm 0 0079 in Axial clearance 0 04 0 08 mm 0 0016 0 0031 in If t...

Page 123: ...e timing chain tensioner Info This requires considerable force since the oil has to be pressed out Release the timing chain tensioner Without pressure the timing chain tensioner expands fully 200172 10 Place two spacing washers or similar aids next to the piston of the timing chain tensioner This should ensure that when pushed down the piston does not fully withdraw Guideline Thickness of spacers ...

Page 124: ... timing chain securing guide for damage and wear If there is damage or wear Replace the timing chain securing guide Check timing chain for damage and wear If there is damage or wear Change the timing chain Check that the timing chain links move easily Let the timing chain hang down freely If the chain links no longer straighten out Change the timing chain 19 20 Removing rocker arm 300113 10 Remove...

Page 125: ...19 22 Removing valves 300115 10 Take the shims out of the valve spring retainers and lay them to one side accord ing to their normal built in position 300116 10 Pretension the valve springs using the special tool Valve spring compressor 59029019000 p 213 Valve spring mounting device 78029060000 p 220 Remove valve keys and release tension on the valve springs Remove spring retainers and spring Pull...

Page 126: ...hs 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 25 Checking 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 retain...

Page 127: ...ine the valve seat Blow compressed air through all oil holes and check that they are clear 19 27 Installing valves 0 0 1 1 0 0 0 0 2 2 0 0 3 3 0 0 5 5 0 0 4 4 300118 01 Position the valve spring cap Install new valve stem seals Install the valves according to their normal built in position Install the valve springs and the spring retainers 300116 11 Pretension the valve springs using the special t...

Page 128: ...arm shafts Guideline Screw rocker arm shaft M6 12 Nm 8 9 lbf ft 19 29 Dismantling antihopping clutch 300120 10 Clamp the clutch in a vise Info Use soft jaws Carefully loosen and gradually remove the special tool 300121 10 Take the clutch out of the vise and lay it on a clean workbench with the outer clutch hub facing down Take the inner clutch hub and release springs out of the outer clutch hub 30...

Page 129: ...sh rod Check the length of clutch springs Clutch spring length 31 5 33 5 mm 1 24 1 319 in If the clutch spring length is less than the specified value Change all clutch springs Check the contact surface of pressure cap for damage and wear If there is damage or wear Change the pressure cap Check the contact surfaces of the clutch facing discs in the outer clutch hub for wear Clutch cage contact sur...

Page 130: ...ing clutch p 128 19 31 Preassembling antihopping clutch 300123 10 Lubricate the clutch discs thoroughly Push the support ring and the pretension ring on to the outer clutch hub Info The pretension ring must be installed so that it is flush with the inner edge on the support ring 300124 10 Position the trimmed clutch facing disc with the notch for the pretension ring on the outer clutch hub Beginni...

Page 131: ... corrosion and stiffness in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate in contact areas for wear If the sliding plate is worn Change the sliding plate Check return surface on the sliding plate for wear If deep notches are present Change the sliding plate Check guide pin for looseness and wear If the guide pin is loose an...

Page 132: ...ed gear Remove the sixth gear idler gear Remove the split needle bearing and stop disk Remove lock ring Remove the third fourth gear sliding gear Remove lock ring Remove stop disk and the fifth gear idler gear Remove the split needle bearing 19 35 Dismantling countershaft 2 2 3 3 1 1 4 4 5 5 6 6 7 7 8 8 9 9 bk bk bl bl bs bs br br bp bp bo bo bn bn bm bm bq bq 300128 01 Fix the countershaft in the...

Page 133: ...7 3 3 500174 01 Check needle bearing for damage and wear If there is damage or wear Change the needle bearing Check the pivot points of main shaft and countershaft for damage and wear If there is damage or wear Change the main shaft and or countershaft Check the tooth profiles of main shaft and countershaft for damage and wear If there is damage or wear Change the main shaft and or countershaft Ch...

Page 134: ...parts carefully before assembling Check the transmission p 131 0 0 3 3 0 0 1 1 0 0 2 2 0 0 4 4 0 0 5 5 0 0 6 60 0 7 7 0 0 9 9 0 0 8 8 0 0 bk bk 0 0 bl bl 300127 01 Fix the main shaft in the vise with the geared end facing downward Guideline Use soft jaws Mount split needle bearing and put on the fifth gear idler gear with the shift dogs facing upward Mount stop disk and lock ring Push on the third...

Page 135: ... gear on the countershaft with the protruding collar facing downward Mount stop disk and lock ring Mount the sixth gear sliding gear with the shift groove facing upward Install lock ring and stop disk Mount needle bearing and the fourth gear idler gear with the collar facing upward Mount needle bearing and the third gear idler gear with the collar facing downward Install stop disk and lock ring Mo...

Page 136: ... is damage or wear Replace the freewheel gear and or the bearing Check the freewheel when removed for damage and wear If there is damage or wear Replace the freewheel Check the toothing of the starter motor for damage and wear If there is damage or wear Replace the starter motor Clamp the minus negative cable of a 12 Volt power supply to the starter motor housing Briefly connect the plus positive ...

Page 137: ... of the freewheel gear If the primary gear does not turn clockwise or if it does not lock counterclock wise Remove the freewheel p 134 Turn the freewheel 180 Install the freewheel p 135 19 42 Installing freewheel 300129 10 Lubricate all parts thoroughly Push the freewheel into the primary gear Info Note the direction of rotation 300128 11 Install the expansion ring 300130 10 Make sure that all lug...

Page 138: ...30 ENGINE WORK ON INDIVIDUAL PARTS 136 300127 11 Insert the lock ring into the groove with suitable pliers and check that it is seated correctly ...

Page 139: ...shaft 300088 10 Lubricate all bearings Assemble the two transmission shafts and slide them into the bearing seats together 300089 10 Mount the upper shift fork the middle shift fork and the lower shift fork Info For the assembly of the middle shift fork the sliding gear of the third fourth gear must be lifted 300090 10 Insert shift drum into the bearing seat Hang the shift forks into the shift dru...

Page 140: ...shaft into the bearing seat and take off the special tool Align marks and Mount stop disk 20 3 Installing left engine case 300077 11 Mount the dowels Mount the O ring Degrease the sealing area Apply the sealing compound to the left engine case half Loctite 5910 300075 11 Put on the left engine case half If necessary tap lightly with a rubber mallet and turn the transmission shafts Info Do not tigh...

Page 141: ... pump covers Mount and tighten the screws Guideline Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Install washers and pins 300070 11 Mount the oil pump gears washers and lock washers 20 5 Installing locking lever 300069 11 Position locking lever with sleeve and spring Mount and tighten screw Guideline Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243 20 6 Installing shift drum locating 300...

Page 142: ...the way Let the sliding plate engage in the shift drum locating Shift through the transmission 20 8 Installing starter drive 300065 11 Install the two needle bearings and the woodruff key Push on the freewheel gear 300064 11 Push on the starter idler gear with washer Mount lock ring Push on the needle bearing and torque limiter with washer Mount lock ring 20 9 Installing primary gear 300063 10 Ens...

Page 143: ...kage in the clutch cage Info If necessary turn the main shaft a little to ease access Make sure that the upper clutch disc is offset by one notch 302121 10 Position a new lock washer and install the nut Lock the clutch cage and primary gear using the special tool and tighten the nut Guideline Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Gear segment 75029081000 p 218 Info Make sure ...

Page 144: ...ion sensor Mount screws but do not tighten them yet Guideline Screw ignition pulse gen erator M6 10 Nm 7 4 lbf ft Loctite 243 Position the cable and push the cable support sleeve into the engine case 20 12 Installing timing chain and timing chain sprocket 300150 10 Heat the timing chain sprocket and push it immediately on to the crankshaft Guideline 100 C 212 F Mount lock ring 300148 11 Thread the...

Page 145: ...t the collar of the screw otherwise the timing chain tension rail could lock and break Check both timing chain rails for freedom of motion 20 14 Installing rotor 300042 10 Ensure that the spring washer is seated properly Degrease the cone of the crankshaft and the rotor Mount the rotor Info Make sure that the crankshaft is not blocked Use the special tool to hold the rotor tight Holding spanner 75...

Page 146: ...d piston into the special tool Piston assembly ring 75029015102 p 215 300033 10 Position the piston on the cylinder using the special tool Push the piston carefully into the cylinder from above The piston rings should not become caught otherwise they may be damaged 300035 10 Ensure that piston marking faces the outfeed side 300034 10 Apply a thin layer of sealing compound in area Loctite 5910 Plac...

Page 147: ...n Turn the special tool counterclockwise thereby pressing the piston pin retainer into the groove Piston pin lock ring insert 75029035000 p 216 Make sure that the piston pin retainer is seated correctly on both sides 300039 10 Remove the cloth Keep the timing chain tensioned Push the cylinder down carefully and let the grooved pins engage 20 18 Installing cylinder head 300029 11 Put on the cylinde...

Page 148: ...3 20 19 Installing camshafts 300163 10 Lay the timing chain over the camshaft Push the timing chain into the bearing seats The middle drill hole of the camshaft and the drill hole of the cylinder head must be aligned Info Make sure that the crankshaft is at top dead center 300022 10 Position the camshaft support plate Mount and tighten screw Guideline Screw camshaft support plate M6 10 Nm 7 4 lbf ...

Page 149: ...tool Crank the engine several times Set the engine to ignition top dead center p 101 300155 10 Check the valve clearance on all valves between the valve and the rocker arm using the special tool Guideline Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Feeler gauge 59029041100 p 214 If valve clearance does not meet specifications Adjust the valve clearance p 147 20 22 Adjusting valve clearance 30015...

Page 150: ...ards 300156 11 Install and tighten the screws of the rocker arm shafts Guideline Screw rocker arm shaft M6 12 Nm 8 9 lbf ft Check the valve clearance p 147 20 23 Installing spark plug 300016 11 Mount and tighten the spark plug using the special tool Guideline Spark plug M12x1 25 17 Nm 12 5 lbf ft Spark plug wrench 75029172000 p 219 20 24 Installing spacer and spring 300154 10 Install the spacer an...

Page 151: ...deline Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 20 27 Installing thermostat 300010 11 Position the thermostat with the gasket The drill hole must face upward Install the thermostat case with the radiator hose Mount and tighten the screws Guideline Screw thermostat housing M6 10 Nm 7 4 lbf ft Loctite 243 20 28 Installing the oil filter 300009 11 Insert the oil filter Lubricate the O r...

Page 152: ...sensor Position O ring 302126 11 Install the gear position sensor Position the ground wire Mount and tighten the screws Guideline Screw gear sensor M5 5 Nm 3 7 lbf ft Loctite 243 20 30 Installing the spacer 302140 10 Grease spacer in area and O ring before mounting Long life grease p 210 Position the O ring in the cut out of the spacer 302124 10 Grease the shaft seal ring Long life grease p 210 Sl...

Page 153: ...ll and tighten the plug with O rings Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 300161 11 Position the oil screen with O rings Install and tighten the plug with O rings Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 20 32 Installing alternator cover 300005 10 Apply sealing compound lightly in the area of the cable support sleeve Install the dowel Put on the alternator cover seal 3000...

Page 154: ... motor Long life grease p 210 Mount and tighten screws Guideline Screw starter motor M6 10 Nm 7 4 lbf ft Loctite 243 20 34 Installing valve cover 300003 10 Put the valve cover in place with the seal Mount and tighten screws Guideline Screw valve cover M6 10 Nm 7 4 lbf ft 20 35 Taking engine off universal mounting rack 300144 11 Remove the screw or the nut Take the engine off the universal mounting...

Page 155: ...ch fluid reservoir mounted on the handlebar to a horizontal position 100281 10 Remove screws Remove cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the level of the coolant does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 209 Position the cover with the membrane Mount and tighten the screws ...

Page 156: ...ine guard p 32 600616 10 Stand the vehicle upright Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Fit screw with a new seal and tighten it Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft Install the engine guard p 32 22 2 Filling the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard Avo...

Page 157: ...ning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of...

Page 158: ...and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition Engine is cold 100283 10 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank The coolant level mus...

Page 159: ... 6 Rocker arm shaft 7 Transmission 8 Clutch 9 Oil jet for piston cooling 10 Oil filter 11 Crankshaft 12 Oil screen 13 Suction pump 7 Transmission 23 2 Checking the engine oil level Info The engine oil level must be checked when the engine is warm Condition The engine is at operating temperature Stand the motorcycle upright on a horizontal surface ...

Page 160: ...le regulations 302039 10 Remove screw 302040 10 Position the banjo bolt with the connector and sealing rings Mount and tighten the banjo bolt Guideline Banjo bolt M10x1 8 Nm 5 9 lbf ft Oil pressure adapter 77329006000 p 219 Connect the pressure tester to the special tool without the T plate Pressure testing tool 61029094000 p 214 Check the engine oil level p 157 Danger Danger of poisoning Exhaust ...

Page 161: ... engine oil p 159 Remove the oil filter p 160 Clean the oil screens p 161 Install the oil filter p 160 Fill up with engine oil p 162 23 5 Draining engine oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous...

Page 162: ...ase filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Place a suitable container under the engine 100202 10 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 p 212 100203 10 Remove screws Remove oil filter with the O ring Pull oil filter out of the oil filter h...

Page 163: ... be disposed of as stipulated in applicable regulations Place a suitable container under the engine 100205 10 Remove screw plug with oil screen and the O rings 100206 10 Remove screw plug with oil screen and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 100207 10 Position oil screen with the O rings Mount and tighten screw plug with the O ring Gu...

Page 164: ...it is oil tight Install the engine guard p 32 Check the engine oil level p 157 23 10 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove the oil filler plug with O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 208 Engine oil SAE 10W 50 p 208 Info For optimal performance of the ...

Page 165: ...1 Stator connector EN pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 Ω If the displayed value is not equal to the setpoint value Replace the stator 600894 10 601014 10 Stator winding check for a short circuit to ground terminal 31 Measure the resistance between the specified points Stator connector EN pin 1 Measuring point Ground Resistance Ω If the displayed value is not equal to th...

Page 166: ...as been removed Remove the fuel tank 600739 13 Ignition coil cylinder 1 check the secondary winding resistance Measure the resistance between the specified points Ignition coil pin 2 Ignition coil pin 3 Ignition coil Resistance of secondary winding at 20 C 68 F 10 4 15 6 kΩ If the displayed value is not equal to the setpoint value Replace the ignition coil ...

Page 167: ...tor drive moves the throttle valve to the basic position completely closed 400790 60 Determine the voltage value via the Test button Info The Continue button only appears if the measured value equals the set point value Throttle position sensor circuit A Basic position voltage THAD 0 50 0 54 V If the displayed value is not equal to the setpoint value Close the menu with Exit Adjust the basic setti...

Page 168: ...6 Close the menu with Continue 25 2 Adjusting the basic setting of the motor drive Condition The diagnostics tool is connected Remove the air filter box p 55 601136 10 Disconnect the connector of the motor drive DR Switch on the ignition by turning the ignition key in the position 690 Enduro EU 690 Enduro AUS UK 690 Enduro USA Select model Select ECU Diagnostics Highlight EPT throttle motor drive ...

Page 169: ...ur finger and hold it Check the voltage value Info The Continue button only appears if the measured value equals the set point value Throttle position sensor circuit A Basic position voltage THAD 0 50 0 54 V If the displayed value is not equal to the setpoint value Repeat the setting Use Continue to start the Adjusting the emergency position of the throttle valve menu Release the throttle valve Fi...

Page 170: ...inue to start the Adjusting the position of the throttle grip sensor menu Check the voltage value Info The Continue button only appears if the measured value equals the set point value Throttle grip sensor Voltage APAD 0 70 0 74 V If the displayed value is not equal to the setpoint value Loosen screws Adjust the accelerator position sensor by turning to the specified value Tighten screws Press Con...

Page 171: ...ases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and perform an initialization run Guideline Initialization run 15 min 25 3 Flashing the EFI control unit and or the EPT contro...

Page 172: ...FI control unit and or the EPT control unit is connected The ignition is on The diagnostics tool is connected and running Flashing of the EFI control unit and or the EPT control unit is completed 400687 60 Select model Select ECU Diagnostics Highlight the Injection management EFI LC4 control unit Press Continue Select Coding Please enter the password Press Continue Select Change VIN New identity P...

Page 173: ... For new control units a sample VIN is displayed For used control units the last programmed VIN is displayed Press Continue Select Code entry Please enter the code Press Continue The new VIN is written to the EFI control unit Switch to the main menu Select Show identification Compare the old VIN to the new VIN The new VIN is shown EPT control unit Select model Select ECU Diagnostics Highlight EPT ...

Page 174: ...41 THROTTLE VALVE BODY 172 Switch to the main menu Select Show identification Compare the old VIN to the new VIN The new VIN is shown ...

Page 175: ...Clutch APTC Antihopping clutch in oil bath hydraulically operated Gearbox 6 gears claw shifted Transmission ratio 1st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 21 23 5th gear 23 22 6th gear 23 20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Alternator 12 V 224 W Spark plug NGK LKAR 8AI 9 Spark plug...

Page 176: ... in Piston ring groove clearance 0 08 mm 0 0031 in Piston ring end gap Compression rings 0 80 mm 0 0315 in Oil scraper ring 1 00 mm 0 0394 in Piston piston pin hole diameter 20 010 20 020 mm 0 78779 0 78819 in Piston pin diameter 19 995 20 004 mm 0 7872 0 78756 in Connecting rod axial clearance of lower conrod bearing 0 40 0 60 mm 0 0157 0 0236 in Connecting rod radial clearance of lower conrod be...

Page 177: ...175 Main shaft axial clearance 0 10 0 40 mm 0 0039 0 0157 in Transmission shaft run out 0 025 mm 0 00098 in Shift shaft play in sliding plate shift quadrant 0 40 0 80 mm 0 0157 0 0315 in Fuel pressure Under every load condition 3 3 3 7 bar 48 54 psi ...

Page 178: ...lbf ft Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw rocker arm shaft M6 12 Nm 8 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 10 Nm 7 4 lbf ft Lo...

Page 179: ...r valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 60 Nm 44 3 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 lbf ft ...

Page 180: ... 32 psi Tire air pressure offroad single rider Front 1 5 bar 22 psi Rear 1 5 bar 22 psi Secondary drive ratio 15 45 Chain 5 8 x 1 4 X ring Steering head angle 63 Wheelbase 1 498 15 mm 58 98 0 59 in Seat height unloaded 910 mm 35 83 in Ground clearance unloaded 300 mm 11 81 in Weight without fuel approx 138 5 kg 305 3 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axl...

Page 181: ... M C 54H TL Metzeler Enduro 3 Sahara 140 80 18 M C 70H TL Metzeler Enduro 3 Sahara 690 Enduro USA 90 90 21 M C 54R TT Pirelli MT 21 RALLYCROSS 130 90 18 M C 69R TT Pirelli MT 21 RALLYCROSS Additional information is available in the Service section under http www ktm com 29 2 Capacity fuel Total fuel tank capacity approx 12 l 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 p 209 Fuel reserve approx ...

Page 182: ...Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer s 472 mm 18 58 in Spring rate Soft 5 2 N mm 29 7 lb in Medium standard 5 4 N mm 30 8 lb in Hard 5 6 N mm 32 lb in Fork length 890 mm 35 04 in Air chamber length 100 30 10 mm 3 94 1 18 0 39 in Fork oil per fork leg 645 ml 21 81 fl oz Fork oil SAE 5 p 209 ...

Page 183: ...Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 19 mm 0 75 in Spring rate Soft 75 N mm 428 lb in Medium standard 80 N mm 457 lb in Hard 85 N mm 485 lb in Spring length 220 mm 8 66 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 80 90 mm 3 15 3 54 in Fitted length ...

Page 184: ...der M6 10 Nm 7 4 lbf ft Loctite 243 Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw ignition lock M6 10 Nm 7 4 lbf ft Loctite 243 Screw magnetic holder on side stand M6 10 Nm 7 4 lbf ft Loctite 243 Screw radiator bracket M6 5 Nm 3 7 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw voltage regulator M6 8 N...

Page 185: ...bearer on frame M10 45 Nm 33 2 lbf ft Screw foot brake lever M10LH 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 lbf ft Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Lambda sensor M12x1 25 24 5 Nm 18 07 lbf ft Copper paste Screw swingarm pivot M12x1 75 80 Nm 59 lbf ft Nut linkage lever on swingarm M14x1 5 100 Nm...

Page 186: ...enhances the corrosive effects of salt After the motorcycle has been thoroughly cleaned with a gentle spray of water it should be dried with compressed air and a cloth Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the engine is warm applying the b...

Page 187: ... it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 184 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion sub stance Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After use on salted roads clean the motorc...

Page 188: ... p 64 Remove the battery p 72 Recharge the battery p 73 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place should be dry and not subject to large temperature differences Info KTM recommends jacking up the motorcycle Raise the motorcycle with the lift stand p 9 Cover the motorcycle with a porous sheet or blanket Info Do not use non porous materials sin...

Page 189: ...brake fluid level p 79 Bleed the fork legs p 12 Check the steering head bearing play p 29 Change the spark plug Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and bellows for cracking leaks and correct routing Check the antifreeze and coolant level p 155 Check the cables for damage and routing without sharp bends Check that the throttle cables are undamaged routed ...

Page 190: ... 1 2 3 2 2 C1 1 G20 2 3 EN 3 1 K11 2 1 4 3 1 AF 4 X13 2 1 a AF 4 X13 3 EB 4 X19 3 4 c 1 0 3 X 2 0 3 X 1 2 A7 A11 43 2 DS 44 X18 43 AU 2 X12 2 EB 4 X19 4 b 10A F9 1 2 FJ 2 X9 1 CR 1 X292 1 CR 1 X291 1 FJ 2 X9 2 wh rd wh rd wh rd bl bl bl bl bl rd bl rd wh rd gn rd bu rd bu br bl gn gn gn br wh rd bl rd wh rd ye rd ye rd br 690 Enduro SMC 08 09 10 600974 01 ...

Page 191: ... Battery G20 Generator K10 Starter relay with main fuse K11 Start auxiliary relay M10 Starter motor T20 Voltage regulator X291 Connector for accessory ground terminal 31 ACC 1 not assigned X292 Connector for accessory plus terminal 30 ACC 1 not assigned ...

Page 192: ...8 DS 44 X18 8 2 d EB 4 X15 3 e S23 BK 4 BK 4 4 3 1 2 EB 4 X14 4 BY 4 X41 3 BY 4 X41 4 3 A3 P10 BR 4 X37 4 2 2 BR 4 X37 3 7 A6 A12 1 DT 36 X21 1 1 DS 44 X18 1 b 1 FJ 2 X1 2 S11 CV 4 CV 4 4 3 2 1 1 ED 32 X63 1 15 ED 32 X63 15 18 ED 32 X63 18 wh rd wh bl wh rd wh rd wh rd rd rd rd ye rd wh bl wh rd wh rd ye rd ye rd ye rd br gn ye rd ye rd br br ye rd ye rd br br bl rd br wh rd bl rd gn br br gr br g...

Page 193: ... 191 A11 EFI control unit A12 EPT control unit F1 Fuse K12 Light relay K30 Power relay P10 Combination instrument S11 Ignition steering lock S23 Emergency OFF switch electric starter button X295 Diagnostics connector ...

Page 194: ...6 B1 f g c d DI 2 X61 1 DI 2 X61 2 3 6 4 2 5 1 5 C1 S29 BC 12 BC 12 E13 1 2 3 2 1 BP 4 X29 2 3 BP 4 X29 4 1 DG 4 X28 2 3 DG 4 X28 4 BW 3 X23 3 3 6 BW 3 X23 2 AC 6 X34 4 2 A3 P10 5 A1 AC 6 X34 5 15A F7 1 2 FJ 2 X7 1 d FJ 2 X7 2 FJ 2 X6 2 8 ED 32 X63 8 1 gr gr gn ye bu ye bu ye br gn bu bu bu gn gn bu gn bu br br br bu bu ye gn ye br gn ye bu gn br ye br br 690 Enduro SMC 08 09 10 600976 01 ...

Page 195: ...WIRING DIAGRAM 193 E13 Low beam high beam F6 Fuse F7 Fuse P10 Combination instrument P15 Horn P35 Parking light S29 High beam low beam switch horn button turn signal switch ...

Page 196: ...P 4 10 f c 3 F8 f c B76 AK 2 AK 2 2 1 AH 2 X26 1 AH 2 X27 1 B77 AK 2 AK 2 2 1 AJ 3 X32 3 E60 1 2 1 AH 2 X27 2 AH 2 X26 2 DI 2 X58 2 DI 2 X58 1 P36 BG 3 BG 3 BS 2 BS 2 1 2 3 1 2 BV 2 X22 1 BV 2 X22 2 AJ 3 X32 2 g wh gn wh gn wh gn ye bu ye bu br ye wh wh br br ye bu br ye ye bu br 690 Enduro SMC 08 09 10 600977 01 ...

Page 197: ...WIRING DIAGRAM 195 B76 Front brake light switch B77 Brake light switch rear E60 License plate lamp P36 Brake tail light ...

Page 198: ... CX 2 X46 2 3 CV 4 X59 4 3 BY 4 X60 4 CX 2 X47 1 CX 2 X46 1 3 C3 S29 BG 3 BG 3 2 3 1 CV 4 X59 2 BY 4 X60 2 AH 2 X20 1 3 A3 P10 7 A1 BT 3 X17 1 2 BT 3 3 AH 2 X20 2 CX 2 X30 1 P42 1 CW 2 2 CW 2 CX 2 X30 2 P41 1 CW 2 2 CW 2 CX 2 X31 1 CX 2 X31 2 10 9 10 ED 32 X63 9 bl pu bl pu br pu bl pu pu bl bl br br ye bu bl or bl or br br bl br pu br ye bu br 690 Enduro SMC 08 09 10 600978 01 ...

Page 199: ...7 K20 Turn signal relay P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 High beam low beam switch horn button turn signal switch ...

Page 200: ...6 5 4 3 2 1 M t 5 F8 3 B8 7 F1 6 10 M14 BI 2 BI 2 1 2 B33 2 1 10A F5 1 2 FJ 2 X5 1 10A F8 1 2 FJ 2 X8 1 AU 2 X10 2 c d AV 2 X33 1 AV 2 X33 2 c CR 1 X294 1 CR 1 X293 1 AU 2 X10 1 FJ 2 X8 2 FJ 2 X5 2 gn bl bl gn wh bl wh bl bl rd bl rd br br gn br br 690 Enduro SMC 08 09 10 600979 01 ...

Page 201: ...RAM 199 B33 Temperature switch for radiator fan F5 Fuse F8 Fuse M14 Radiator fan X293 Connector for accessory ground terminal 31 ACC 2 not assigned X294 Connector for accessory plus terminal 15 ACC 2 not assigned ...

Page 202: ...M60 FK 8 7 8 6 5 4 3 2 1 30 29 24 31 14 16 15 13 30 1 29 2 24 3 31 4 14 5 16 6 15 7 DT 36 X21 13 DR 8 X39 8 2 A1 A12 DT 36 X21 36 35 10 AP 6 X295 4 10A F3 1 2 FJ 2 X3 1 5 A1 P10 8 A7 FJ 2 X2 2 FJ 2 X4 2 FJ 2 X3 2 24 ED 32 X63 24 br pu bu gr ye rd ye rd bl bu wh bu gn or bl bu or br bl bu rd gn bl bu br wh gn wh rd wh or bu rd gn bl bu br wh gn wh rd wh or bu br br bl rd bl rd ye rd bu or br pu br ...

Page 203: ...WIRING DIAGRAM 201 A11 EFI control unit A12 EPT control unit F2 Fuse F3 Fuse F4 Fuse M13 Fuel pump M60 Motor drive P10 Combination instrument X295 Diagnostics connector ...

Page 204: ...DF 2 X40 2 18 DS 44 X18 18 41 DS 44 X18 41 22 DS 44 X1822 FM 1 X48 1 12 DS 44 X18 12 FS 4 X45 2 42 42 4 25 25 i FS 4 X45 1 M20 1 2 7 A1 P10 9 A7 DW 2 X42 1 DQ 2 X43 1 2 ED 32 X63 2 B70 CZ 3 CZ 3 1 2 3 CY 3 X62 3 23 23 1 3 ED 32 X63 3 CY 3 X62 2 40 4 DS 44 40 4 or bl or rd gr bl gr wh pu gn rd lbu bl bl or rd gr bl gr wh pu gn rd lbu or or or or or bl or bl or bu br bl or bu br bl or or wh bu wh bu...

Page 205: ... EFI control unit B51 Lambda sensor cylinder 1 B70 Front wheel speed sensor M20 Fuel evaporation valve USA version only M21 Secondary air valve M51 Injector cylinder 1 P10 Combination instrument R51 Ignition coil cylinder 1 ...

Page 206: ...R 3 X49 3 DS 44 X18 26 32 31 10 32 1 31 2 DS 44 X18 10 AM 3 X50 3 15 DS 44 X18 15 AP 6 X51 5 34 DS 44 X18 34 i i AR 3 X49 2 4 4 DS 44 X18 4 j 1 AP 6 X51 6 11 13 DS 44 X18 13 AM 3 X36 1 DS 44 X18 11 AR 3 X35 2 AR 3 X35 3 AM 3 X36 3 1 2 8 A7 P10 10 A7 CM 2 X16 2 CM 2 X16 1 11 ED 32 X63 11 pk ye br gr bl gn bl gn ye gn rd bu ye or wh pk pk ye br gr bl gn ye gn ye or wh pk bl bl bu bu bl bl bu bu rd b...

Page 207: ... A11 EFI control unit B10 Throttle position sensor circuit A B12 Intake air temperature sensor B26 Rollover sensor B30 Side stand switch B31 Accelerator position sensor B34 Gear position sensor P10 Combination instrument ...

Page 208: ...52 2 14 DP 3 X53 3 DS 44 X18 14 35 DS 44 X18 35 c AL 2 X54 1 44 20 DS 44 X18 20 44 DV 2 X55 2 33 DS 44 X18 33 DV 2 X55 1 2 DS 44 X18 2 AL 2 X54 2 36 36 1 EC 3 X57 3 38 38 i DP 3 X53 2 EC 3 X57 2 1 j AT 2 X56 2 AT 2 X56 1 B32 AL 2 AL 2 1 2 9 A7 P10 5 5 12 ED 32 X63 12 7 ED 32 X63 7 wh ye ye bu gn gr pu br br bl br ye bl ye wh wh ye ye bu gn gr pu bl br ye bl ye bu or br rd br br bl bl bl bu bu br w...

Page 209: ...e sensor cylinder 1 B32 Fuel level indicator B37 Crankshaft position sensor B38 Clutch switch B41 Manifold absolute pressure sensor cylinder 1 P10 Combination instrument S55 Map Select Switch bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 210: ...nhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 224 SAE p 224 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex produc...

Page 211: ...line Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 224 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and tha...

Page 212: ...Motorex products Supplier Motorex Accu Contact High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 Lubricant T158 Guideline KTM recommends Lubcon products Supplier Lubcon Turmogrease PP 300 Lubricant T511 Guideline KTM recommends Lubcon products Supplier Lubcon Turm...

Page 213: ...r Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 214: ... 01 Art no 15112017000 Insert for bearing puller 400125 01 Art no 15112018100 Feature 18 23 mm 0 71 0 91 in Bleed syringe 400058 01 Art no 50329050000 Circlip pliers reverse 400059 01 Art no 51012011000 Extractor 400073 01 Art no 58429009000 ...

Page 215: ...nner bearing race 400082 01 Art no 58429037043 Mounting sleeve 400095 01 Art no 58529005000 Valve spring compressor 400101 01 Art no 59029019000 Limit plug gauge 400104 01 Art no 59029026006 Extractor 400105 01 Art no 59029033000 ...

Page 216: ...12 5 3 5 400110 01 Art no 59029041100 Hose clamp pliers 400142 01 Art no 60029057000 Pliers for spring loaded band type clamp 400085 01 Art no 60029057100 Testing hose 201314 01 Art no 61029093000 Pressure testing tool 400149 01 Art no 61029094000 ...

Page 217: ... 200306 01 Art no 61229001000 Work stand 400151 01 Art no 62529055000 Support for engine work stand 400153 01 Art no 75012001060 Holder for engine work stand 400154 01 Art no 75012001070 Piston assembly ring 400156 01 Art no 75029015102 ...

Page 218: ...tor 400157 01 Art no 75029021000 Assembly screws 400158 01 Art no 75029033000 Piston pin lock ring insert 400160 01 Art no 75029035000 Work stand adapter 400161 01 Art no 75029036000 Push in drift 500163 01 Art no 75029044010 ...

Page 219: ... Art no 75029044020 Pressing device for crankshaft complete 400185 01 Art no 75029047000 Upper part pressing out tool 400186 01 Art no 75029047050 Under part pressing out tool 400187 01 Art no 75029047051 Extractor 400162 01 Art no 75029048000 ...

Page 220: ...mping plate 400163 01 Art no 75029050000 Push out drift 400164 01 Art no 75029051000 Floor jack attachment 400184 01 Art no 75029055000 Mounting sleeve 400165 01 Art no 75029080000 Gear segment 400068 01 Art no 75029081000 ...

Page 221: ...n cover 400167 01 Art no 75029090000 Holding spanner 400168 01 Art no 75029091000 Spark plug wrench 400170 01 Art no 75029172000 Oil pressure adapter 400176 01 Art no 77329006000 Engine blocking screw 400177 01 Art no 77329010000 ...

Page 222: ...se device for timing chain tensioner 400181 01 Art no 77329051000 Valve spring mounting device 500165 01 Art no 78029060000 Spring compressor 300573 10 Art no T101S Hook wrench 301085 01 Art no T106S Pin 201235 10 Art no T120 ...

Page 223: ...ECIAL TOOLS 221 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S Vacuum pump 200273 10 Art no T1240S Pressing tool 200584 01 Art no T129 Protecting sleeve 200635 10 Art no T1401 ...

Page 224: ...L TOOLS 222 Clamping stand 200688 10 Art no T14016S Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art no T1402S Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S ...

Page 225: ...SPECIAL TOOLS 223 Mounting sleeve 300569 10 Art no T1515 Filling adapter 300567 10 Art no T1516 Hook wrench 200899 10 Art no T157S Pin 200687 10 Art no T605 ...

Page 226: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 227: ...r installing 152 water pump cover mounting 149 B Battery connecting 73 disconnecting 72 fitting 72 recharging 73 removing 72 Brake discs checking 65 Brake fluid front brake adding 80 front brake changing 80 rear brake adding 84 rear brake changing 85 Brake fluid level front brake checking 79 rear brake checking 84 Brake linings front brake changing 77 front brake checking 77 rear brake changing 82...

Page 228: ...hecking measuring 118 electric starter drive checking 134 freewheel checking 135 freewheel installing 135 freewheel removing 134 left engine case section 112 main shaft assembling 132 main shaft disassembling 130 oil pumps for wear checking 120 piston ring end gap checking 119 piston checking measuring 118 piston cylinder mounting clearance checking 120 right engine case section 111 rocker arm ins...

Page 229: ...57 Oil filter changing 159 installing 160 removing 160 Oil screens cleaning 159 161 P Parking light bulb changing 90 Play in throttle cable adjusting 31 checking 30 Protective treatment for winter operation 185 Putting into operation after storage 186 R Rear hub rubber dampers checking 70 Rear sprocket checking 68 Rear wheel installing 66 removing 66 Riding sag adjusting 36 Rim run out checking 71...

Page 230: ...assembling 23 Technical data chassis 178 179 chassis tightening torques 182 183 engine 173 engine tolerance wear limits 174 175 engine tightening torques 176 177 fork 180 shock absorber 181 Tire air pressure checking 64 Tire condition checking 64 Type label 7 W Warranty 6 Wiring diagram 188 207 page 1 of 10 188 page 10 of 10 206 page 2 of 10 190 page 3 of 10 192 page 4 of 10 194 page 5 of 10 196 p...

Page 231: ... 3206041en 3206041en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 02 2010 Photo Mitterbauer ...

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