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KTM 690 Enduro AUS 2010, Repair Manual

The KTM 690 Enduro AUS 2010 Repair Manual is a comprehensive guide that provides detailed instructions and diagrams for repairing and maintaining your motorcycle. This manual is available for free download on our website, allowing you to access vital information easily and conveniently at manualshive.com.

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04/SHOCK ABSORBER, SWINGARM

43

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. 44)

–

After removing the shock absorber, clean it thoroughly.

201271-11

–

Loosen locking ring

.

–

Turn adjusting ring

until the spring is no longer under tension.

Hook wrench (T106S) (

p. 254)

–

Measure the overall spring length without a load.

–

Tension the spring by turning the adjusting ring

to the prescribed value.

Guideline

(690 Enduro)

Spring preload

20 mm (0.79 in)

(690 Enduro R)

Spring preload

20 mm (0.79 in)

Info

Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.

–

Tighten locking ring

.

–

Install the shock absorber. (

p. 45)

8.8

Adjusting the riding sag

–

Remove the shock absorber. (

p. 44)

–

After removing the shock absorber, clean it thoroughly.

201352-10

–

Choose and mount a suitable spring.
Guideline

(690 Enduro)

Spring rate

Medium (standard)

80 N/mm (457 lb/in)

(690 Enduro R)

Spring rate

Medium (standard)

80 N/mm (457 lb/in)

Info

The spring rate is shown on the outside of the spring.

–

Install the shock absorber. (

p. 45)

–

Check the static sag of the shock absorber. (

p. 42)

–

Adjust the rebound damping of the shock absorber. (

p. 41)

Summary of Contents for 690 Enduro AUS 2010

Page 1: ...REPAIR MANUAL 2009 690 Enduro EU 690 Enduro AUS UK 690 Enduro R EU 690 Enduro R AUS UK 690 Enduro R USA Article no 3206076en ...

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: ... of the shock absorber 42 Adjusting the spring preload of the shock absorber 43 Adjusting the riding sag 43 Removing the shock absorber 44 Installing the shock absorber 45 Servicing the shock absorber 46 Removing the spring 46 Dismantling the damper 47 Disassembling the piston rod 48 Checking the damper 49 Removing the heim joint 50 Installing the heim joint 51 Assembling the piston rod 52 Assembl...

Page 5: ...WORK ON INDIVIDUAL PARTS 122 Work on the right section of the engine case 122 Work on the left section of the engine case 123 Work on the clutch cover 124 Removing crankshaft bearing inner ring 125 Removing balancer shaft drive wheel 125 Changing the conrod bearing 125 Checking crankshaft run out at bearing pin 127 Installing balancer shaft drive wheel 127 Installing crankshaft bearing inner ring ...

Page 6: ...g the basic setting of the motor drive 179 Flashing the EFI control unit and or the EPT control unit 182 Requesting the enabling code 183 Coding the EFI control unit and or EPT control unit 184 TECHNICAL DATA ENGINE 186 Capacity engine oil 186 Capacity coolant 186 TECHNICAL DATA TOLERANCE WEAR LIMITS OF ENGINE 187 TECHNICAL DATA ENGINE TIGHTENING TORQUES 189 TECHNICAL DATA CHASSIS 191 Lighting equ...

Page 7: ...age reference more 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 below Specific name Indicates a proprietary name Name Identifies a protected n...

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: ...06 01 The 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 n...

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: ...rd under the motorcycle The wheels must no longer touch the ground Secure the motorcycle against falling over 4 2 Removing the motorcycle from the lift stand 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 w...

Page 12: ...ger 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 ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic compo...

Page 13: ...fore trying again This motorcycle is equipped with a safety start system You can only start the engine if the gearbox is in neutral or if the clutch is pulled when a gear is engaged If the side 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...

Page 14: ... Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection covers 5 2 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 100244 10 690 Enduro Turn adjusting screws clockwise until they stop Info The ad...

Page 15: ...ork Mount and tighten bleeder screws Info Carry out this action on both fork legs 800091 10 690 Enduro R Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Info Carry out this action on both fork legs 5 4 Cleaning the dust boots of the fork legs Raise the motorcycle with the lift stand p 9 Loosen the fork protection p 14 100293 ...

Page 16: ... on the right fork leg Push the fork protection downwards 5 6 Positioning the fork protection 800075 11 690 Enduro Position the fork protection on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and wiring harness Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten t...

Page 17: ...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 18: ...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 19: ...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 20: ... of the rebound and compression damping 200643 10 Clamp the fork leg in the area of the lower triple clamp Clamping stand T1403S p 257 200737 10 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 200738 10 Push the outer tube downward Pull the spring downward Mount the special tool on the hexagon Open ...

Page 21: ...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 22: ...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 23: ... washer and spring seat off of the cartridge 200749 10 Degrease the cartridge and clamp it with the special tool Clamping stand T14015S p 256 Heat the cartridge in area Guideline 50 C 122 F Loosen and remove screw sleeve Info This operation is not needed for further disassembly 200697 10 Degrease the piston rod Clamp the piston rod with the special tool Clamping stand T14016S p 256 200698 10 Remov...

Page 24: ...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 18 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 25: ...tube 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 2006...

Page 26: ...ed value Increase the strength of the preload spacers 5 14 Checking the fork legs 690 Enduro R Condition Fork dismantled 200728 10 Check the inner tube and the axle clamp for damage If damage is found Replace the inner tube 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 th...

Page 27: ...d value Reduce the strength of the pretensioning bushes If the measured value is less than the specified value Increase the strength of the preload spacers 5 15 Assembling the 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 244 200705 10 Mount shim sta...

Page 28: ...cant T158 p 244 Mount spring 200718 10 Lubricate the O ring of tap rebound Lubricant T158 p 244 Mount and tighten the tap compression Guideline Tap rebound M9x1 18 Nm 13 3 lbf ft Loctite 2701 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 p...

Page 29: ...t will go Info The fluid barrier must be tightened as much as possible Do not use tools 5 17 Assembling the fork legs 690 Enduro Info These operations are the same on both fork legs Check the fork legs p 23 Assemble the cartridge p 26 Assemble the tap compression p 25 200669 10 Clamp the inner tube with the axle clamp Mount the special tool Protecting sleeve T1401 p 255 Grease and push on dust boo...

Page 30: ...g bushing Info Without using a tool carefully pull the stack apart by hand 200723 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 256 Press on the outer tube as far as it will go 200724 10 Position the support ring Hold the seal ring with the sh...

Page 31: ...e Gripping tool T14026S1 p 256 Info The special tool must be used to prevent the adjusting tube being lifted and thus to prevent oil from reaching 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 ve...

Page 32: ...rod is stiff it must be held to prevent it from turning If the screw cover is not screwed to the stop the rebound adjustment will not work correctly Tighten the screw cover Guideline Screw cover on piston rod M12x1 25 Nm 18 4 lbf 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 ...

Page 33: ...e slowly at first to get the feel of the new ride behavior Turn the adjusting screws to the position they were in before dismantling Mount protection cap 5 18 Assembling the fork legs 690 Enduro R Info These operations are the same on both fork legs Check the fork legs p 24 Assemble the cartridge p 26 Assemble the tap compression p 25 200669 10 Clamp the inner tube with the axle clamp Mount the sp...

Page 34: ... 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 256 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 256 Press on the outer tube as far as ...

Page 35: ... prevent oil from reaching 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 635 ml 21 47 fl oz Fork oil SAE 5 p 243 Info Pull out and push in t...

Page 36: ...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 257 Grease the O ring of the screw cover Lubricant T158 p 244 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 37: ... with the lift stand p 9 100298 10 Move 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 35 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the en...

Page 38: ...10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Check the steering head bearing play p 35 Remove the motorcycle from the lift stand p 9 ...

Page 39: ...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 40: ...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 41: ...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 42: ...ort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn 690 Enduro R Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 8 2 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to i...

Page 43: ...ger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided 100247 10 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 690 Enduro Rebound damping Comfort 20 clicks Standard 15 clicks ...

Page 44: ...ro Static sag 25 mm 0 98 in 690 Enduro R Static sag 25 mm 0 98 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 43 8 6 Checking the riding sag of the shock absorber 0 0 A A 0 0 C C 400990 10 Measure distance of rear wheel unloaded p 42 With another person holding the motorcycle the rider wearing full protective cloth ing sits on the se...

Page 45: ... load Tension the spring by turning the adjusting ring to the prescribed value Guideline 690 Enduro Spring preload 20 mm 0 79 in 690 Enduro R Spring preload 20 mm 0 79 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten locking ring Install the shock absorber p 45 8 8 Adjusting the riding sag Remove the shock absorber p 4...

Page 46: ... with the work stand p 9 300562 10 Remove screws 300563 10 Lift the rear fairing Remove screws 300564 10 Remove screw Repeat the operation on the opposite side 300565 10 Loosen screw Remove screw Remove screw 300566 10 Swing the rear end upwards Lift shock absorber upwards and remove ...

Page 47: ...w Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 300564 11 Mount and tighten screw Guideline Screw fuel tank bottom M8 20 Nm 14 8 lbf ft Repeat the operation on the opposite side 300563 11 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 11 Mount and tighten screws Guideline Screw side cov...

Page 48: ...e the heim joint p 50 Install the heim joint p 51 Assemble the piston rod p 52 Assemble the damper p 53 Install the spring p 58 8 12 Removing the spring Condition The shock absorber has been removed 201271 10 Clamp the shock absorber in the vise using soft jaws for protection Measure and note spring length in preloaded state Loosen retaining ring and the adjusting ring with the special tool Hook w...

Page 49: ...ing Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reservoir Open screw slowly The pressurized nitrogen escapes 201274 10 Remove locking cap 201276 10 Press in seal ring retainer Remove lock ring Info Do not scratch the inner surface 201277 10 Remove screw Drain the oil 201278 10 Remove the piston rod Drain the remaining oil ...

Page 50: ...40 10 Clamp the piston rod with the heim joint in a vise Remove nut 300541 10 Remove supporting plate and rebound shim stack together with piston Info Thread the rebound shim set on a screwdriver and set the parts down together 200572 11 Remove compression shim stack with supporting plate Info Thread the compression shim stack on a screwdriver and set the parts down together ...

Page 51: ...greater than the specified value Change the damper cartridge Check the damper cartridge for damage and wear If there is damage or wear Change the damper cartridge 300554 10 Measure the diameter of the piston rod Piston rod Diameter 17 95 mm 0 7067 in If the specification is not reached Change the piston rod Measure the run out of the piston rod Piston rod Run out 0 03 mm 0 0012 in If the measured ...

Page 52: ...oint 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 254 Turn over the shock absorber and remove collar bushing of the heim joint Pin T120 p 254 200578 10 Remove seal rings on both sides 200579 10 Remove lock rings on both sides ...

Page 53: ...lling 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 255 Pressing tool T129 p 255 200579 11 Mount lock rings on both sides 200578 11 Mount seal rings on both sides and grease them Lubricant T158 p 244 200582 10 Press in both collar sleeves of the heim joint ...

Page 54: ... T625 p 245 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 201270 10 Sand both sides of the piston on a surface plate using 1200 grit sandpaper Clean the piston Assemble the piston Guideline View Piston from above View Piston from below 300541 11 Mount the rebound shim stack with...

Page 55: ...t 201277 11 Mount and tighten screw Guideline Filling port screw M10x1 14 Nm 10 3 lbf ft 201288 10 Fill the damper cartridge about half full Shock absorber oil SAE 2 5 50180342S1 p 243 201278 11 Grease O ring of the seal ring retainer Lubricant T158 p 244 Mount the piston rod carefully 201276 10 Install the seal ring bearer and push it under the ring groove Mount lock ring Info Do not scratch the ...

Page 56: ...eed 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 suspens...

Page 57: ... point The piston rod slides in and out during filling do not hold it tight with your hand 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 The vacuum gauge falls to the specified value 4 mbar 201...

Page 58: ...m gauge falls to the specified value 4 mbar 200267 10 When the vacuum pressure gauge reaches the specified value turn theOil reser voir control lever to Equalize Pressure Guideline 4 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 pres...

Page 59: ... and tighten screw Guideline Filling port screw M10x1 14 Nm 10 3 lbf ft 8 21 Filling the damper with nitrogen 201282 10 Screw in screw by approx 2 rotations but do not tighten Info The piston rod is fully extended 201281 10 Clamp special tool in the vise Nitrogen filling tool T170S1 p 257 Connect the special tool to the pressure regulator of the filling cylinder Filling gas nitrogen Adjust pressur...

Page 60: ... Mount spring retainer The open end is opposite the spring end 201271 11 Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline Spring preload 20 mm 0 79 in Hook wrench T106S p 254 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 t...

Page 61: ...ot touch hot components Remove the air filter box p 63 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 62: ... 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 64 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 63: ...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 64: ...05 EXHAUST 62 302046 11 Mount and tighten screws Guideline Rear fairing screw M5 2 Nm 1 5 lbf ft ...

Page 65: ...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 66: ...r spring loaded band type clamp 60029057100 p 248 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 248 300205 11 Position the air fil...

Page 67: ... 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 67 ...

Page 68: ... at the same time Pull back the seat and lift it off 11 4 Mounting the seat 100276 10 690 Enduro 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 seat is correctly mounted 800096 10 690 Enduro R Hook slo...

Page 69: ...le 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 Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin ar...

Page 70: ...el pressure When the fuel pump is active 3 3 3 7 bar 48 54 psi If the specification is not reached Open the filler cap p 66 Check the tank air vent system 400928 01 Check the fuel pressure with the filler cap open Fuel pressure When the fuel pump is active 3 3 3 7 bar 48 54 psi If the specification is not reached Check that the fuel line is clear Change the fuel filter p 68 Replace the fuel pump S...

Page 71: ... contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Disconnect the battery p 81 Drain the fuel from the fuel tank into a suitable container 300562 10 Remove screws 3005...

Page 72: ...ng 302608 11 Mount fuel filter Arrow points away from the fuel pump Mount hose clamps Hose clamp pliers 60029057000 p 248 302607 10 Position the fuel pump Mount and tighten screws Guideline Screw fuel 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 ...

Page 73: ...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 Disconnect the battery p 82 ...

Page 74: ...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 75: ...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 76: ... 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 77: ... 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 79 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 78: ...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 79: ...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 80: ...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 81: ...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 75 13 9 Checking the spoke tension Warning Dange...

Page 82: ...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 83: ...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 84: ...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 85: ...d Remove the seat p 66 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 86: ...individual power consumers is located under the seat Switch off all power consumers and switch off the engine Remove the seat p 66 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 87: ...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 Set the Map Select swit...

Page 88: ...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 89: ... 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 90: ...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 91: ...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 242 Position the cover with the membrane Mount and tight...

Page 92: ...Level 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 242 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 93: ...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 94: ...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 95: ...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 93 15 13 Adding rear brake fluid Warning Danger of accidents Failure of the brake system If the brake f...

Page 96: ...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 97: ...d to the MAX mark Brake fluid DOT 4 DOT 5 1 p 242 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 98: ...m km h to mph or from mph to km h Guideline Activation duration of M button 10 s 16 2 Setting the clock Condition The motorcycle is stationary 700115 10 690 Enduro Switch on the ignition by turning the ignition key to position ON 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 MO...

Page 99: ... the M button repeatedly until the Trip 1 mode is active Keep the S button pressed The Trip 1 display is set to 0 00 16 4 Combination instrument setting resetting TRIP 2 Info The TRIP 2 trip counter runs constantly and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts ...

Page 100: ... Press and hold the MODE button for 10 seconds The wheel circumference is displayed in millimeters 302053 10 Increasing the wheel circumference Press the MODE button Reducing the wheel circumference Press the SET button Keep the MODE button and the SET button pressed simultaneously The settings are saved and the Setup menu is closed Switch off the ignition by turning the ignition key to position O...

Page 101: ...10 690 Enduro R Loosen screw Adjust the light range by swiveling the headlight Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark made in Checking headlight adjustment Info If you have a heavy payload you will need to correct the headlight range Tighten screw 16 8 Removing the headlight mask with the headlight Switch off all power consumers and switch o...

Page 102: ...eadlight mask with the headlight 16 9 Installing the headlight mask with the headlight 100294 11 690 Enduro Connect the connectors of headlight and turn signal lights Check lighting function 100295 10 Remove the cloth from the fender attach the headlight mask to points on the fender and swing it up to the steering head 100296 12 Position brake hose guide Mount and tighten screws Guideline Remainin...

Page 103: ...ng 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 mounting Remove the headlight mask with the headlight p 99 600610 12 690 Enduro Remove rubber cap 600612 10 Pull bulb socket out of the reflector Pull parking light bulb out of the bulb socket Insert a new park...

Page 104: ... with the headlight p 99 600610 10 690 Enduro Pull off connector Take off rubber cap of the headlight bulb 600611 10 Detach spring bar Remove headlight bulb Insert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 192 Fix the headlight bulb in the headlight using the spring bar Replace the rubber cap Attach the connector 800098 10 690 Enduro R Pull off connectors and Take ...

Page 105: ...n signal bulb carefully into the socket and turn it clockwise until it stops Turn signal R10W socket BA15s p 192 Mount the orange plug Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly 100160 10 690 Enduro R USA Remove the screw on the rear of the turn signal housing Tilt headlamp diffuser forward carefully and take ...

Page 106: ...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 107: ...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 108: ...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 252 300225 11 Position the engine in the frame Mount swingarm pivot Mount...

Page 109: ...Guideline 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 Plier...

Page 110: ...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 111: ... radiator hoses Install the spring loaded band type clamps Install the exhaust manifold p 59 Disconnect the battery p 82 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 242 Alternative engine oil Engine oil SAE 10W 50 p 242 Install and tighten the oil filler plug with O ring Fill the coo...

Page 112: ...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 113: ...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 246 ...

Page 114: ... 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 253 1...

Page 115: ... 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 253 ...

Page 116: ...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 117: ... the special tool to hold the rotor tight Holding spanner 75029091000 p 253 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 246 Remove the special tool 18 20 Removing timing chain rails 3000...

Page 118: ...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 247 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 119: ... 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 252 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 120: ... 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 121: ...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 122: ...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 123: ... 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 124: ...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 125: ... 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 126: ...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 127: ...balancer shaft drive wheel Remove the crankshaft bearing inner ring p 125 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 125 300137 10 Position the crankshaft with the special tool in the press Under part pressing out tool 75029047051 p 251 Positio...

Page 128: ...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 251 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 129: ...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 127 19 9 Installing crankshaft bearing inner ring 300134 10 Fix the crankshaft with special t...

Page 130: ...s too large add compensation shims Install the crankshaft bearing inner ring p 127 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 131: ...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 248 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 132: ...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 133: ...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 134: ...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 135: ... 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 136: ...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 247 Valve spring mounting device 78029060000 p 254 Remove valve keys and release tension on the valve springs Remove spring retainers and spring Pull...

Page 137: ...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 138: ...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 139: ...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 140: ...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 141: ...ing clutch p 139 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 142: ... 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 143: ...t in the vise with the geared end facing downward Guideline Use soft jaws Remove stop disk and second gear fixed 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 690 Enduro R ...

Page 144: ...ear 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 bearing bush 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 vise with the geared end facing downward Guideli...

Page 145: ...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 Check the pivot po...

Page 146: ...haft 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 Check the pivot points of idler gears for damage and wear If there is damage or wear Change the idler fixed gear pair Check the shift dogs of id...

Page 147: ... assembling Check the transmission p 143 690 Enduro EU 9 9 7 7 5 5 4 4 3 3 2 2 1 1 bl bl bk bk 6 6 8 8 301980 02 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 fourth gear sliding gear with the small gear wheel...

Page 148: ...op disk and lock ring Push on the third fourth gear sliding gear with the small gear wheel pointing downward and mount lock ring Push on stop disk and split needle bearing Put on the sixth gear idler gear with the shifting claws facing downward Mount the second gear fixed gear with the collar facing downward and mount stop disk Finally check all gear wheels for smooth operation 19 38 Assembling co...

Page 149: ...ng 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 Mount the fifth gear sliding gear with the shift groove facing downward and stop disk Mount needle bearing first gear idler gear with the groove facing downward ...

Page 150: ... 12 Volt power supply to the starter motor housing Briefly connect the plus positive cable of the power supply to the starter motor connection If the starter motor does not turn when you close the power circuit Replace the starter motor Replace the O ring of the starter motor 19 40 Removing freewheel 300127 10 Extract the lock ring from the groove using suitable pliers 300128 10 Compress the expan...

Page 151: ...primary gear Info Note the direction of rotation 300128 11 Install the expansion ring 300130 10 Make sure that all lugs of the expansion ring locate in the slits of the freewheel Info If necessary use a screwdriver to ease them in 300127 11 Insert the lock ring into the groove with suitable pliers and check that it is seated correctly ...

Page 152: ...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 153: ...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 154: ... 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 155: ...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 156: ...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 252 Info Make sure ...

Page 157: ...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 158: ...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 159: ...d piston into the special tool Piston assembly ring 75029015102 p 249 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 160: ...n Turn the special tool counterclockwise thereby pressing the piston pin retainer into the groove Piston pin lock ring insert 75029035000 p 250 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 161: ...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 162: ...tool Crank the engine several times Set the engine to ignition top dead center p 112 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 248 If valve clearance does not meet specifications Adjust the valve clearance p 160 20 22 Adjusting valve clearance 30015...

Page 163: ...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 160 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 253 20 24 Installing spacer and spring 300154 10 Install the spacer an...

Page 164: ...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 165: ...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 244 Position the O ring in the cut out of the spacer 302124 10 Grease the shaft seal ring Long life grease p 244 Sl...

Page 166: ...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 167: ... motor Long life grease p 244 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 168: ...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 243 Position the cover with the membrane Mount and tighten the screws ...

Page 169: ...uard p 39 600616 10 Stand the motorcycle upright Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Mount the screw with a new seal ring and tighten it Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft Install the engine guard p 39 22 2 Filling the cooling system Warning Danger of poisoning Coolant is poisonous and a health h...

Page 170: ...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 171: ...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 172: ... 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 173: ...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 253 Connect the pressure tester to the special tool without the T plate Pressure testing tool 61029094000 p 248 Check the engine oil level p 170 Danger Danger of poisoning Exhaust ...

Page 174: ...ine oil p 172 Remove the oil filter p 173 Clean the oil screens p 174 Install the oil filter p 173 Fill up with engine oil p 175 23 5 Draining the 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 175: ...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 246 100203 10 Remove screws Remove oil filter with the O ring Pull oil filter out of the oil filter h...

Page 176: ...d etc should be disposed of as stipulated in applicable regulations Place a suitable container under the engine 100205 10 Remove plug with oil screen and the O rings 100206 10 Remove 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 plug with the O ring Guidelin...

Page 177: ...it is oil tight Install the engine guard p 39 Check the engine oil level p 170 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 242 Engine oil SAE 10W 50 p 242 Info For optimal performance of the ...

Page 178: ...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 179: ...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 180: ...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 181: ... of the motor drive p 179 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 63 601136 10 Disconnect the connector of the motor drive DR Switch on the ignition by turning the ignition key to position ON Select model Select ECU Diagnostics Highlight EPT throttle motor drive control LC4 control unit...

Page 182: ...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 183: ...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 184: ...ess 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 control unit Condition The ignition is on The diagnostics tool is con...

Page 185: ... 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 Press Continue R...

Page 186: ... 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 187: ...41 THROTTLE VALVE BODY 185 Switch to the main menu Select Show identification Compare the old VIN to the new VIN The new VIN is shown ...

Page 188: ...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 189: ... 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 190: ...188 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 191: ...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 192: ...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 193: ... 1 8 bar 26 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 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 690 Enduro 1 498 15 mm 58 98 0 59 in Seat height unloaded 690 Enduro 910 mm 35 83 in Seat height unloaded 690 Enduro R 930 mm 36 61 i...

Page 194: ...ocket BAY15d 12 V 21 5 W License plate lamp W5W socket W2 1x9 5d 12 V 5 W Validity Front tire Rear tire 690 Enduro 90 90 21 M C 54H TL Metzeler Enduro 3 Sahara 140 80 18 M C 70H TL Metzeler Enduro 3 Sahara 690 Enduro R USA 90 90 21 M C 54R TT Pirelli MT 21 RALLYCROSS 140 80 18 M C 70R TT Pirelli MT 21 RALLYCROSS Additional information is available in the Service section under http www ktm com 29 2...

Page 195: ...n Air chamber length 120 20 mm 4 72 0 79 in Fork length 890 mm 35 04 in Fork oil per fork leg 620 ml 20 96 fl oz Fork oil SAE 5 p 243 30 2 690 Enduro R Fork part number 14 18 7E 41 Fork WP Suspension 4860 MXMA Compression damping Comfort 20 clicks 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 Sp...

Page 196: ...0 mm 8 66 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 70 80 mm 2 76 3 15 in Fitted length 395 mm 15 55 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 243 31 2 690 Enduro R Shock absorber part number 15 18 7E 41 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payloa...

Page 197: ...TECHNICAL DATA SHOCK ABSORBER 195 Static sag 25 mm 0 98 in Riding sag 70 80 mm 2 76 3 15 in Fitted length 405 mm 15 94 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 243 ...

Page 198: ...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 199: ...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 200: ...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 201: ... it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 198 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 202: ... p 73 Remove the battery p 81 Recharge the battery p 82 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 203: ... dust boots of the fork legs p 13 Check the front brake fluid level p 88 Bleed the fork legs p 13 Check the steering head bearing play p 35 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 168 Check the cables for damage and routing without sharp bends Ch...

Page 204: ...2 EM 3 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 205: ... 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 206: ...7 A3 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...

Page 207: ... 205 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 208: ...X25 1 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 209: ...WIRING DIAGRAM 207 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 210: ... 5 F1 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 211: ...WIRING DIAGRAM 209 B76 Front brake light switch B77 Brake light switch rear E60 License plate lamp P36 Brake tail light ...

Page 212: ... X47 2 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 213: ...1 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 214: ...1 8 7 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 215: ...RAM 213 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 216: ... 3 c 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 p...

Page 217: ...WIRING DIAGRAM 215 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 218: ...18 17 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...

Page 219: ... 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 220: ... 26 AR 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...

Page 221: ... 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 222: ...L 2 X52 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...

Page 223: ...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 224: ...4 1 2 3 0 2 T 0 1 G BI 2 EM 3 1 2 3 2 1 2 C1 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 CR 1 X291 1 10A F9 1 2 FJ 2 X9 1 CR 1 X292 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 br wh rd ye rd ye rd 600990 01 ...

Page 225: ... 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 226: ...1 C8 1 c 1 c AP 6 X295 6 1 A5 A11 7 A3 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 CZ 3 2 CY 3 X62 2 BR 4 X37 4 2 2 BR 4 X37 3 7 A6 A12 1 DT 36 X21 1 1 DS 44 X18 1 DO 8 1 DN 8 X63 1 b 1 FJ 2 X1 2 S11 CV 4 CV 4 4 3 2 1 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...

Page 227: ... 225 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 228: ...25 1 f g c Up Down Mode d 3 6 4 2 5 1 5 C1 S29 BC 12 BC 12 2 1 BP 4 X29 2 BP 4 X29 3 4 1 DG 4 X28 2 DG 4 X28 3 4 3 6 AC 6 X34 4 2 A3 P10 5 A1 DO 8 4 DN 8 X63 4 AC 6 X34 5 15A F7 1 2 FJ 2 X7 1 1 2 3 DB 4 4 d FJ 2 X7 2 FJ 2 X6 2 S36 DA 4 1 2 3 4 E13 1 1 1 FF 1 X434 1 FF 1 X435 1 FP 1 X436 1 DI 2 X437 2 DI 2 X437 1 gr gr gn ye bu ye bu ye br gn bu bu bu gn gn bu br ye gn ye br gn ye bu gn br ye br br...

Page 229: ...IRING DIAGRAM 227 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 S36 Tripmaster switch optional ...

Page 230: ...5 F1 5 F1 P 4 10 690 Enduro R 09 10 f c f 3 F8 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 600993 01 ...

Page 231: ...WIRING DIAGRAM 229 B76 Front brake light switch B77 Brake light switch rear E60 License plate lamp P36 Brake tail light ...

Page 232: ...CW 2 1 CW 2 f c c CX 2 X47 2 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 2 DO 8 3 2 DN 8 X63 3 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 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 600994 01 ...

Page 233: ...1 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 234: ...3 2 1 8 7 6 5 4 3 2 1 M t 5 F8 3 B8 7 F1 6 10 690 Enduro R 09 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 600995 01 ...

Page 235: ...RAM 233 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 236: ...9 20 10 27 27 X300 8 8 3 3 c 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 CZ 3 1 CY 3 X62 1 FJ 2 X2 2 FJ 2 X4 2 FJ 2 X3 2 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...

Page 237: ...WIRING DIAGRAM 235 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 238: ... 1 DW 2 X42 2 DQ 2 X43 2 FL 1 X44 1 3 7 A3 A11 9 A1 17 DS 44 X18 17 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 DS 44 X18 25 i FS 4 X45 1 M20 1 2 7 A1 P10 9 A7 CZ 3 3 CY 3 X62 3 DW 2 X42 1 DQ 2 X43 1 B70 CZ 3 3 2 1 1 2 3 CY 3 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 bl 600997 ...

Page 239: ... 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 240: ...3 2 3 1 8 A1 A11 10 A1 26 AR 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 DO 8 6 DN 8 X63 6 CM 2 X16 2 CM 2 X16 1 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...

Page 241: ... 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 242: ... 1 23 DS 44 X18 24 AL 2 X52 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 DO 8 7 DO 8 8 DN 8 X63 8 5 DN 8 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 ...

Page 243: ...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 244: ...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 258 SAE p 258 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 245: ...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 258 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and tha...

Page 246: ...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 247: ...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 248: ... 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 249: ...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 250: ...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 251: ... 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 252: ...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 253: ... 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 254: ...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 255: ...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 256: ...se device for timing chain tensioner 400181 01 Art no 77329051000 Valve spring mounting device 500165 01 Art no 78029060000 Hook wrench 301085 01 Art no T106S Depth micrometer 300577 10 Art no T107S Pin 201235 10 Art no T120 ...

Page 257: ...ECIAL TOOLS 255 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 258: ... TOOLS 256 Clamping stand 200733 10 Art no T14015S 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 ...

Page 259: ...SPECIAL TOOLS 257 Clamping stand 200637 10 Art no T1403S Mounting sleeve 300569 10 Art no T1515 Nitrogen filling tool 300574 10 Art no T170S1 ...

Page 260: ...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 261: ...nstalling 165 water pump cover mounting 162 B Battery connecting 82 disconnecting 81 fitting 81 recharging 82 removing 81 Brake discs checking 74 Brake fluid front brake adding 89 front brake changing 89 rear brake adding 93 rear brake changing 94 Brake fluid level front brake checking 88 rear brake checking 93 Brake linings front brake changing 86 front brake checking 86 rear brake changing 91 re...

Page 262: ...tric starter drive checking 147 freewheel checking 148 freewheel installing 149 freewheel removing 148 left engine case section 123 main shaft assembling 145 main shaft disassembling 141 oil pumps for wear checking 131 piston ring end gap checking 130 piston checking measuring 129 piston cylinder mounting clearance checking 131 right engine case section 122 rocker arm installing 137 rocker arm rem...

Page 263: ... 173 Oil screens cleaning 172 174 P Parking light bulb changing 101 Play in throttle cable adjusting 38 checking 37 Protective treatment for winter operation 199 Putting into operation after storage 200 R Rear hub rubber dampers checking 79 Rear sprocket checking 77 Rear wheel installing 75 removing 75 Riding sag adjusting 43 Rim run out checking 80 S Seat mounting 66 removing 66 Service schedule ...

Page 264: ...is tightening torques 196 197 engine 186 engine tolerance wear limits 187 188 engine tightening torques 189 190 fork 193 shock absorber 194 195 Tire air pressure checking 73 Tire condition checking 73 Turn signal bulb changing 103 Type label 7 W Warranty 6 Wiring diagram 202 241 page 1 of 10 202 222 page 10 of 10 220 240 page 2 of 10 204 224 page 3 of 10 206 226 page 4 of 10 208 228 page 5 of 10 2...

Page 265: ... 3206076en 3206076en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 02 2010 Photo Mitterbauer ...

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