KTM 690 Enduro R 2018 Repair Manual Download

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The

engine

number

stamped

the

left

side of the

engine

under the

engine sprocket.

401949-

The

key

number

can

found

the

KEYCODECARD.

Kia

Info

You need

the

key

numberto order

spare

key. Keep

the KEYCODECARD

safe

place.

402241-10

The fork

part

number

stamped

the inner

side of the fork

stub.

401947-10

The shock absorberarticle number

the left side of the

———~"_402025-10

shock absorber.

Summary of Contents for 690 Enduro R 2018

Page 1: ...REPAIR MANUAL 2018 690 Enduro R Art no 3206323en...

Page 2: ......

Page 3: ...nt 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 noliabilityfor delive...

Page 4: ...k protector 18 6 7 Removingthefork legs 0 0eee 18 6 8 Installing the fork legs eee ee 20 6 9 Disassemblingthe fork legs 22 6 10 Checking the fork legs ceceee 25 6 11 Assemblingthe fork legs 06 26 6 12...

Page 5: ...tor c ceeeee 109 BRAKESYSTEMccoscsswsssconerocsrenevexiniceseconeney 110 15 1 Antilock brake system ABS 110 16 17 15 2 Checking the front brake linings 15 3 Changing the front brake linings 15 4 Check...

Page 6: ...ing lever 0 152 17 4 34 Disassemblingthe main shaft 183 17 3 29 Removing the oil pumps 152 17 4 35 Disassemblingthe 17 3 30 Removing the left engine case 154 CouNtershathisiisccicssisecdssssccasseases...

Page 7: ...16 22 25 26 27 28 21 5 Draining the engine oil 08 21 6 Removing the oil filter 0 21 7 Installing the oil filter 21 8 Cleaning the oil screens 21 9 Fillingup with engine oil 21 10 Addingengine Oil eee...

Page 8: ...SUBSTANCES ccsscesscevessnnsenevenaveseoanemnmneenne 278 30 AUXILIARYSUBSTANCES cesseeeeeeeeee 280 31 SPECIAL TOOLS cceceeeeceeeeeeeeeeeeeeeeeeeees 282 32 STANDARDSuccesccscsssscsscerssazsassazeeceeve...

Page 9: ...icates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates a resistance measurement Indicates the end of an activity including potential rework The t...

Page 10: ...erious injury if the appropriate measures are not taken A Caution Indicates a danger thatmay lead to minor injuries if the appropriate measures are not taken Note Indicates a dangerthatwill lead to co...

Page 11: ...the environment Do not allow fuel to enter the groundwater the soil or the sewage system Use the operating and auxiliarysubstances such as fuel and lubricants as specified in the manual Only use spare...

Page 12: ...401945 10 690 Enduro R EU The type label 1 is located on the right side of the frame LN i Nee Ho1049 10 690 Enduro R US The type label USA is located on the right side of the frame The type label Can...

Page 13: ...er can be found on the KEYCODECARD O Kia e Info You need the key numberto order a spare key Keep the KEYCODECARDin a safe place 402241 10 The fork part number oO is stamped on the innerside of the for...

Page 14: ...inst falling over 4 401942 01 Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Remove the motorcycle from the lift stand and rest it on...

Page 15: ...poisoning Exhaustgasesaretoxicand inhalingthem mayresultinunconsciousnessanddeath Alwaysmakesurethere is sufficientventilationwhenrunningtheengine Usean effectiveexhaustextractionsystem whenstartingor...

Page 16: ...trying again This motorcycle is equipped with a safety starting sys tem You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the...

Page 17: ...Turn the emergency OFF switch to the position Shift gear to neutral Switch on the ignition Press the electric starter button N B00103 10 e Info Do not open thethrottle 15...

Page 18: ...type Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks e Info Turn clockwise to increase damping turn counterclock wise to reduce damping e Inf...

Page 19: ...cycle with a lift stand 9 p 12 Loosen the fork protection p 18 Main work Push dust boots of both fork legs downward e Info i The dust boots remove dust and coarse dirt particles from the inside fork t...

Page 20: ...nt and tighten screws Guideline Remaining screws M6 10 Nm 7 4 Ibf ft chassis Position the brake line wiring harness and clamp Mount and tighten screws Position the fork protector on the right fork leg...

Page 21: ...accidents Reduced braking effect caused by damaged brake discs Always lay the wheel downin such a way thatthe brake discs are not damaged Holding the front wheel withdrawthe wheel spindle Take the fro...

Page 22: ...it Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Slide the fork legs into the triple clamps on bothsides Info e l The bleeder screws must face forwards The second gro...

Page 23: ...Clean the brake discs with brake cleaner when nec essary Clean screw andthewheel spindle Jack up the front wheel into the fork position it and insert the wheelspindle Mountandtighten screw Guideline S...

Page 24: ...he fork legs have been removed Makea note of the present state of rebound oo and compres sion damping Note down the current state of the spring preload Completely open the adjusters of the rebound dam...

Page 25: ...down Pull the spring downward Mount the special tool on the hexag onalpart Open end wrench T14032 p 299 e Info Preload spacers should be above the specialtool Clamp the special tool in the vise Loose...

Page 26: ...derneathasoil will run out in most cases Removethecartridge Remove dust boot Remove lock ring QD Info The lock ring has a beveled end where a screwdriver can be applied Warm up the outer tube in area...

Page 27: ...clamp for damage If there is damage Change the inner tube GO0865 10 Measure the outside diameter at several locations on the inner tube Outside diameter of inner 47 975 48 005 mm tube 1 88878 1 88996...

Page 28: ...fied value Reducethethicknessof the preload spacers If the measured value is less than the specified value Increase the thicknessof the preload spacers e Info The operations are the same on both fork...

Page 29: ...hing e Info Without using a tool pull the stack slightly apart by hand Warm up the outer tube in area of the lower sliding bush ing Guideline 50 C 122 F Slide the outer tube onto the inner tube Hold t...

Page 30: ...onents that belongtogether e Info i Compression dampingside cartridge with additionaloil holes 8 white adjuster axle clamp marked L Rebound dampingside cartridge without additionaloil holes red adjust...

Page 31: ...otrudes more than 7 mm 0 275in from the cartridge and cannot be pressedin against the spring force Lubricate the thread of the piston rod Lubricant T159 p 280 Lubricate the upper edge of the piston ro...

Page 32: ...the screw Guideline Adapter M4x0 5 1 5 Nm b 1 11 Ibf ft ra ae e Info il Compression damping side white adjuster axle clamp f marked L 202322 10 Rebound dampingside red adjuster axle clamp marked R Al...

Page 33: ...ic Turn the adjustingscrews to the position theywere in before dismantling Warning Dangerof accidents Incorrect steering head bearingplay impairs the handlingcharacteristicand dam ages components Corr...

Page 34: ...eparatory work Raise the motorcycle with a lift stand p 12 Main work Loosen screws Loosen screw Loosen and retighten screw Guideline Screw top steering M20x1 5 12 Nm 8 9 Ibf ft head Using a plastic ha...

Page 35: ...ndlebar clamps Remove the handlebar and lay it to one side e Info Cover the components to protect them against damage Do not bendthecables andlines Remove screws Remove the handlebar support Place the...

Page 36: ...tory work Remove the headlight mask with the headlight p 128 Removetheseat p 73 Main work Removethecable tie s Remove screws ep Take off the side cover Remove the cable tie s Remove screw Push the tri...

Page 37: ...tion sensor Disconnect plug in connector G00707 10 Remove screws Remove the combinationinstrument upwards out of the holder and hangto theside Loosen screw GO0709 10 Remove screws 6 Take off hand guar...

Page 38: ...position sensor on the handlebar Catch engages in driver GOO0713 10 Mount and tighten screws Guideline Screw throttlegrip M5 3 5 Nm 2 58 Ibf ft Catch engagesin recess GO00714 10 Position hand guard M...

Page 39: ...le tie s Position the combinationinstrument in the holder Mount and tighten screws Guideline Remaining screws M4 4 Nm 3 Ibf ft chassis Mountand tighten screw Qe Guideline Remaining screws M4 4 Nm 3 Ib...

Page 40: ...cableties G00703 10 Finishingwork Install the headlight mask with the headlight p 129 Checkthe headlight setting p 127 Reset the engine electronics control unit p 236 Program the gear position sensor...

Page 41: ...theleft and right Pull the engine guard forward out of the holders and removeit Slide the engine guard into holders 0 at the rear Position the engine guard Mount and tighten screws Qe Guideline Remain...

Page 42: ...g Turn counterclockwise by the numberof turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn e In...

Page 43: ...ting the rebound damping of the shock absorber A Caution Risk of injury Parts of the shock absorberwill move aroundif the shock absorber is detached incorrectly The shock absorberis filled with highly...

Page 44: ...motorcycle from the lift stand p 12 400989 10 Measure distance o of rear wheel unloaded p 42 Hold the motorcycle upright with the aid of an assistant Measure the distance betweentherear axle and the f...

Page 45: ...44 Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorberis filled with highly compressed nitrogen Please follow the desc...

Page 46: ...the work stand p 12 Removetheseat 1 p 73 Take off the side cover p 73 Remove the shock absorber p 45 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring...

Page 47: ...motorcycle with the work stand p 12 Removetheseat p 73 Take off the side cover p 73 Main work Remove screws Remove the battery cover Detach connector Lift the rear fairing Remove screws 3 G00742 10 R...

Page 48: ...rae oe SS owe ws Main work Insert shock absorber 0 from above Lowertherear WS 4 Se Mount screw butdo nottighten yet Guideline Screw top M10 45 Nm 33 2 Ibfft shock absorber Loctite 243TM Mount and tigh...

Page 49: ...en screw Guideline 6 Screw fuel M8 tank bottom 25 Nm 18 4 Ibfft Loctite 243TM Lift the rearfairing Mount and tighten screws Guideline Screw main silencer holder on fuel tank M8 25 Nm 18 4 Ibf ft Plug...

Page 50: ...ovethespring p 48 Dismantlethe damper p 49 Disassemble the piston rod p 50 Check the damper p 51 Remove the heim joint p 52 Install the heim joint 2 p 53 Assemble the piston rod p 54 Assemble the damp...

Page 51: ...ote the current state of the rebound damping and compression damping Completely open the adjustersof the rebound and compression damping Remove rubber cap Oo of the reservoir Open screw slowly The pre...

Page 52: ...remainingoil 201278 10 Remove compression adjuster Removethespring sleeve and piston 4 201279 10 Preparatorywork Remove the spring p 48 Dismantlethe damper p 49 Main work Clampthepiston rod with the h...

Page 53: ...and set the parts down together 200572 11 Removesealring retainer Remove locking cap andrubber buffer Condition The damper has been disassembled Measure the inside diameter at both ends andin the cen...

Page 54: ...the piston rod Checkthe piston rod for damage and wear If there is damage or wear Change the piston rod Check the heim joint for damage and wear If there is damageor wear Change the heim joint 4 Ss Ly...

Page 55: ...special tool 6 underneathand press out the heim joint with special tool Pressing tool T1207S p 297 Place special tool Oo underneathand push the heim joint to the middle using special tool Pressing too...

Page 56: ...m joint in a vise Guideline Use soft jaws Mount rubber buffer and locking cap Position special too on the piston rod Mounting sleeve T1515 p 299 Grease the seal ring and pushsealring retainer o on to...

Page 57: ...semble the piston Guideline View Piston from above View Piston from below Mountthe rebound shim stack with the smallershims fac ing upward Install supporting plate Mount and tighten nut Guideline Pist...

Page 58: ...Oe Guideline Compression adjuster M26x1 30 Nm 22 1 Ibf ft Mountandtighten screw Guideline Filling port screw M10x1 14 Nm 10 3 Ibfft Clamp the damper in the vise using soft jaws Fill the damper cartri...

Page 59: ...ck Turn counterclockwise by the numberof clicks correspond ing to the shock absorbertype Guideline Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 cl...

Page 60: ...urn adjustingscrews o and oO to the position determined during disassembly Finishingwork Install the spring p 62 4 e Info Before working with the vacuum pump besure to read the operating instructions...

Page 61: ...atingpiston is positioned all the way at the bottom 201285 10 When the vacuum pressure gauge reachesthespecified value turn the Oil reservoir control lever 8 to Equalize pressure Guideline 4 mbar The...

Page 62: ...o Pressure Guideline 0 bar Oil is pumped into the damper The pressure gaugerises to the specified value 3 bar Whenthe pressure gauge reachesthespecified value turn the Damper control lever to Vacuum G...

Page 63: ...rt screw M10x1 14 Nm 10 3 Ibfft 201282 10 201281 10 Screw in screw by approx 2 rotations but do nottighten e Info The piston rod is fully extended Clamp special tool in the vise Fillingtool T170S1 p 3...

Page 64: ...the vise with soft jaws Mount retaining ring oO and turn it down as far as possible Thecollar points to the adjustingring Mount adjustingring andturnit all the way down Thecollar faces the spring Mea...

Page 65: ...se a serious deterioration in the handling characteristicand overload components Only make adjustmentswithinthe recommendedrange Ride slowlyto start with after making adjust ments to get the feel of t...

Page 66: ...the vehicle Preparatorywork Removetheseat p 73 Take off the side cover p 73 Main work Remove cable ties O Push the cable to the right Disconnect plug in connector of the lambda sensor Feed out the cab...

Page 67: ...nderhead Copper paste Position the exhaust clamp Tighten screw e Guideline Screw main M8 12 Nm 8 9 Ibf ft silencerclamp Copper paste Position the exhaust clamp Mount and tighten screw Guideline Screw...

Page 68: ...shingwork Mount the side cover p 74 Mounttheseat p 73 _ Warning Danger of burns The exhaustsystem gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any w...

Page 69: ...encer holder M8 25 Nm 18 4 Ibf ft Mountandtighten screws Guideline Rearfairing screw M6 5 Nm 3 7 Ibfft Position the exhaust clamp Tighten screw Guideline Screw main M8 silencerclamp 12 Nm 8 9 Ibfft Co...

Page 70: ...without an airfilter Removeair filter Main work Clean the airfilter box Mountair filter 7 e Info il Theair filter must lie flush against the air filter box rO along the entire sealing surface lf the a...

Page 71: ...Take off the side cover p 73 Main work Remove screws Take off the voltage regulator and hangit to the side in a de energized state Remove screws Remove screws Detach vent hose 4 Loosen hose clip Rais...

Page 72: ...and tighten screws Guideline Screw air filter box M6 6 Nm 4 4 Ibf ft on frame Route vent hose e without bends and mount Mount and tighten screws OQ Guideline Screw air filter box M6 6 Nm 4 4 Ibf ft on...

Page 73: ...Plug in connector GO00741 12 Finishing work Mount the side cover p 74 Mounttheseat p 73 71...

Page 74: ...case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughlywith water and consult a doctor in case of fuel contact with the eyes Change your clothingin case of fuel sp...

Page 75: ...ame time pushit forward Push locking pin into lock housing 0 and pushthe backof the seat down until the locking pin locks in place with an audibleclick Check finally thatthe seat is correctly mounted...

Page 76: ...el is spilled wipe it off immediately Observethespecificationsfor refueling A Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothingcontact with fuel Immediately...

Page 77: ...deline Minimum size fuel can 10 2 6 USgal Execute Actuator Test Functiontest of fuel pump control Guideline Maximum duration of the 3 min actuatortest Check the fuel pressure with thefillercap closed...

Page 78: ...eyes thoroughlywith water and consult a doctor in case of fuel contact with the eyes Change your clothingin case of fuel spills on them Warning Environmental hazard Improper handling of fuel is a dang...

Page 79: ...water Rinse theeyes thoroughlywithwater and consultadoctor incase of fuelcontactwiththeeyes Changeyourclothingincase offuel spillson them Keepfuels correctlyin a suitablecanister and outof thereachof...

Page 80: ...Lift the rear fairing Remove screws Remove screws onbothsides Swing the rear end upward and secureit G00743 12 Remove screws 6 and take off the splash protector GO00747 10 Remove screws 6 Pull out the...

Page 81: ...mps Removefuelfilter Mount the new fuelfilter Arrow points away from the fuel pump Mount hose clamps Hose clampplier 60029057000 p 286 Press locking mechanism onboth sides Pull off the fuel pump housi...

Page 82: ...ws M5 4 Nm 3 Ibfft Position the rear end Mount and tighten screws on both sides Guideline Screw fuel M8 tank bottom 25 Nm 18 4 Ibf ft Loctite 243TM Lift the rear fairing Mount and tighten screws Guide...

Page 83: ...Environmental hazard Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughlywith water and consult a doctor in case of fuel contact wit...

Page 84: ...off the splash protector Remove screws Pull out the fuel pump Disconnect both fuel hose connections 6 Unplug connector Remove fuel pump Connect new fuel pump connecting both fuel hose connec tions Plu...

Page 85: ...Guideline Screw fuel M8 25 Nm 18 4 Ibf ft tank bottom Loctite 243TM Lift the rearfairing Mount and tighten screws eQ Guideline Screw main silencer M8 25 Nm 18 4 Ibf ft holder on fuel tank G00742 12 Mo...

Page 86: ...a tire bursts while riding thevehicle becomes uncontrollable Ensure that damaged or worn tires are replaced immediately Warning A Danger of crashing Different tire tread patterns on the front and rear...

Page 87: ...ed in the tire label and is indicated by the last four digits of the DOT number Thefirst two digits indicate the week of manufacture andthe last two digits the year of manu facture KTM recommendsthatt...

Page 88: ...n break dueto local overload Check the spoketension regularly especially on a new motorcycle Brieflystrike each spoke with a screwdriver blade e Info l The frequencyof the tone is a function of the sp...

Page 89: ...eater than the specified value Center the rim e Info i Center the rim by tightening the spoke nipple on the opposite side of the rim run out Change the rim if it is excessively deformed Correct the sp...

Page 90: ...ver when the front wheel is removed Remove spacers _ Warning Dangerof accidents Oil or grease on the brake discs reducesthe brakingeffect Always keepthebrake discs free of oil and grease Clean the bra...

Page 91: ...en screws Guideline Screw fork stub m8 15 Nm 11 1 Ibfft Position wheel speed sensor in the drill hole Mount and tighten screw Guideline Screw wheel speed M6 6 Nm 4 4 Ibf ft sensor e Info If the brake...

Page 92: ...le 6 NN BH 801969 10 Push the rear wheel forward as far as possible and take the chain off the rear sprocket _ Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the...

Page 93: ...sprocket carrier in the rear wheel Position the rear wheel The brake linings are correctly positioned Push the rear wheel forward as far as possible and lay the chain on the rear sprocket Mount wheel...

Page 94: ...rews Guideline Screw rear M6 14 Nm 10 3 Ibf ft brake disc Loctite 243TM Finishingwork Install the rear wheel p 90 Remove the motorcycle from the lift stand p 12 Checkthechain tension p 92 4 13 7 4 Che...

Page 95: ...chain tension p 93 02193 10 13 7 5 Adjustingthe chain tension fyWarning _ Danger of accidents Incorrect chain tension damages componentsand results in accidents If the chain is tensioned too much the...

Page 96: ...esure that the chain adjusters are installed correctly on adjustingscrews Tighten nut Guideline Nut rear wheel spin M25x1 5 90 Nm 66 4 Ibf ft dle 4 13 7 6 Adjustingchain guide 2 Remove screws rt and T...

Page 97: ...u should repeat this measurementat different chain positions Maximum distance at 272 mm 10 71 in the longest chain section f the distance is greater than the specified measure ment Change the powerset...

Page 98: ...id M8 15 Nm ing piece 11 1 Ibf ft Check the chain guide for wear e Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide Check that...

Page 99: ...old grease residue with chain cleaner Chain cleaner p 280 After drying apply chain spray Off road chain spray p 280 400725 01 Finishing work Remove the motorcycle from thelift stand p 12 13 7 9 Checki...

Page 100: ...to turn the rear sprocket with your hand e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear s 5 mm s 0 2 in wheel If clearance o larger than the specified value Ch...

Page 101: ...area immediatelywith plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the...

Page 102: ...t the battery into the battery compartment with the termi nals facingrearward Battery YTZ10S p 243 Position retaining bracket oO and mount and tighten screws Guideline e Remaining screws M6 10 Nm 7 4...

Page 103: ...p 73 Main work Remove battery cover Disconnect negative cable of the battery e Info i Never operate the motorcycle with a discharged battery or without a battery In both cases electrical compo nents...

Page 104: ...ironmental hazard Hazardous substances cause environmental damage Dispose ofoils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Ev...

Page 105: ...e professional 00029095053 p 283 e Info Follow the charger s instructions exactly Disconnect the battery charger after charging the battery Guideline The charging current charging voltage and charging...

Page 106: ...If the displayed valueis less than the specified value Checkthe plug in connections from the alternator to the voltage regulator Check the plug in connections from the voltage regula tor to the wiring...

Page 107: ...ent between battery ground and the nega tive cable Info The value of the open circuit current only applies to vehicles in their original state without additional power consumers Maximum open circuit c...

Page 108: ...ion key to position OFF Remove theseat p 73 Main work Take off protection caps Remove a defective main fuse with needle nosepliers e Info I A defective fuse is indicated by a burned out fuse wire A sp...

Page 109: ...adiator fan Fuse 5 10 A horn brake light turn signal Fuse 6 15 A high beam low beam parkinglight tail light license plate lamp Fuse 7 10 A for auxiliaryequipment permanent positive Fuse 8 10 A for aux...

Page 110: ...Set the adjustingwheel to position 1 Soft reduced homologated peak performance for bet ter driveability Set the Map Select switch to Advanced Set the adjustingwheel to position 2 Advanced homologated...

Page 111: ...02172 10 Diagnosticsconnector oO is located under the engine control unit 109...

Page 112: ...h a high center of gravity varying road surfaces steep descents or full braking without disengaging the gear Adapt yourridingstyleto the road conditions and your driving ability The ABS operates with...

Page 113: ...ng If there is wearor tearing Change the front brake linings p 111 94 801959 01 4 Warning Danger of accidents Incorrect maintenancewillcause the brake system tofail Ensure that service work and repair...

Page 114: ...rdous substances cause environmental damage Dispose ofoils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brakeflu...

Page 115: ...luid DOT 4 DOT5 1 p 278 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water _ Warning nt Dangerof accidents The bra...

Page 116: ...accidents An insufficient brake fluid level will cause the brake system tofail If the brake fluid level drops below the specified markingor the specified value the brake system is leaking or the brak...

Page 117: ...g change the clothing Warning Dangerof accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordancewiththe service schedule War...

Page 118: ...hing change theclothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance wit...

Page 119: ...rake fluid emerges in the bleeder bot tle hose without bubbles Tighten the bleeder screw Close shut off valve Open the bleeder screw again until brake fluid stops emerging e Info Overfillingof the bra...

Page 120: ...re that service work and repairs are performed professionally _ Warning Skin irritation Brake fluid causes skin irritation Keep brakefluidout of the reach of children Wearsuitable protective clothinga...

Page 121: ...d brake lines are not designed for DOT 5 brakefluid Avoid contact between brakefluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Stand the vehicle up...

Page 122: ...d stop and the contact to the foot brake cylinder piston and check f ___ free travel I 4 Guideline Free travel at foot brake lever 3 5mm 0 12 0 2 in f 9 e Info O S 55 You will know thatcontact has bee...

Page 123: ...oot brake lever p 120 Tighten nut B01291 10 _ Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the MIN marking the...

Page 124: ...on to your clothing change the clothing _ Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with...

Page 125: ...mage Disposeofoils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid...

Page 126: ...ithout bubbles Tighten the bleeder screw Close shut off valve Open the bleederscrew again until brake fluid stops emerging e Info Overfillingof the brake fluid reservoir is prevented Tighten the bleed...

Page 127: ...dition The motorcycle is stationary Switch on the ignition by turning the ignition key to position ON Press the MODE button repeatedly until the ODO modeis active ae kash Keep the MODE button and the...

Page 128: ...ve Keep the SET button pressed The TRIP 2 display is set to 0 0 401446 01 16 1 5 Setting the wheel circumference Danger Voiding of thegovernmentapprovalfor road use and the insurance coverage The vehi...

Page 129: ...rom the combinationinstrument Connect pin 18 to connector ED Plug connector ED into the combinationinstrument Finishing work Install the headlight mask with the headlight p 129 Checkthe headlight sett...

Page 130: ...Checking the headlight setting e Info i Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a payload you may have to correct the headlight...

Page 131: ...ition line guides 4 Mount and tighten screws 6 Guideline Screw headlight M5 5 Nm 3 7 Ibf ft mask Finishing work Checkthe headlight setting p 127 Note Damage to reflector Grease on the reflector reduce...

Page 132: ...gwork Install the headlight mask with the headlight 2 p 129 Checkthe headlight setting p 127 4 Note Damageto reflector Grease on the reflector reduces the brightness Grease on the bulb will evaporate...

Page 133: ...uch the bulbs with your bare hands Main work 690 Enduro R EU Remove the screw onthe rear of the turn signal housing Tilt headlamp diffuser forward carefully and takeit off Lightly squeeze orange cap i...

Page 134: ...t e Info Do not touch the reflector with your fingers and keepit free from grease 601889 10 Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal RY...

Page 135: ...air filter box p 69 Remove the manifold 9 p 64 Remove the engine guard p 39 Drain the coolant p 218 Main work Loosen hoseclips eo using the special tool Pull off the radia tor hoses Hose clampplier 60...

Page 136: ...cket Remove screws Remove cable ties Take off the clutch slave cylinderwith the gasket and hangit to the side e Info l Do not kink the clutch line Do not activate the clutch lever whilethe slave cylin...

Page 137: ...ier 60029057100 p 286 Pull off the hoses Unplug connector from the oil pressure sensor Remove screw Release connection Take off the line with the oil pressure sensor Remove screws Removefitting Take o...

Page 138: ...against damage GOO771 10 Preparatory work Lift the engine onto the special tool and secureit Floor jack attachment 75029055000 p 292 Main work Position the engine in the frame e Info ll The help of an...

Page 139: ...2 80 Nm 59Ibfft pivot Tighten the lower engine bracket Guideline Engine carrying M10 45 Nm 33 2 Ibf ft screw Loctite 243TM Position the line with the oil pressure sensor Mount and tighten connection G...

Page 140: ...cal connection on the starter motor Mount and tighten screw Mount the protection cap Guideline Screw cable on M5 3 Nm 2 2 Ibf ft starter motor Position the ground wire on the starter motor Mount and t...

Page 141: ...le Have an assistant operate the rear brake Tighten the engine sprocket nut Guideline Nut engine M20x1 5 80 Nm 59Ibfft sprocket Loctite 243TM Secure the nut with lock washer Position the engine sprock...

Page 142: ...bleedthe cooling system p 218 Remove the motorcycle from the work stand p 13 Perform theinitializationrun p 236 Go for a short test ride Read out the fault memory using the KTM diagnostics tool Check...

Page 143: ...the magnetandsealring Remove plug with oil screen and the O rings Remove plug with oil screen andtheO rings Completely drain the engineoil 4 Removeoil throttle oO Take off the starter motor 4 Remove s...

Page 144: ...ake off the alternator cover Take off alternator cover gasket and remove dowels 17 3 6 Removingthe spacer Remove spacer 305521 10 17 3 7 Removingthe gear position sensor Remove screws Pp with the wash...

Page 145: ...r cover with the O ring Removeoil filter Lock ring plier 51012011000 p 284 4 17 3 9 Removingthe thermostat Remove screws O Take off the thermostat case Remove thermostat e 4 oS be 305528 10 17 3 10 Se...

Page 146: ...tool Locking screw 77329010000 4 p 294 4 17 3 11 Removingthe spark plugs Remove spark plugs and Spark plug wrench 75029172000 p 293 4 305516 10 17 3 12 Removingthe timing chain tensioner Remove screw...

Page 147: ...off the cylinderhead gasket Remove screw Push the cylinderupward e Info i Push the cylinder upward only far enoughto allow removalof the piston pin Ensure thatthe two grooved pins remain in place Remo...

Page 148: ...t the two grooved pins remain in place Remove screws Take off the water pump cover Remove screw Remove water pump impeller Take off the water pump coverseal e Info Ensure the locating pins remain in p...

Page 149: ...uring guide e Info The support bushing is plugged into the timing chain securing guide through the timing chain guiderails Remove the timing chain guide rails upward out of the timing chain shaft Hold...

Page 150: ...3000 p 286 17 3 20 Removingthe ignition pulse generator Remove screws O Pull cable sleeve outof the enginecase Remove the ignition pulse generator 17 3 21 Removingthe clutch cover Remove screws Takeof...

Page 151: ...cial tool by hand only do not use another tool Loosen screws diagonallyand remove them with their spring retainers and clutch springs Removepressure cap Remove clutch throw out Bend up lock washer Hol...

Page 152: ...move the special tool Gear segment 75029081000 p 292 Take out the antihopping clutch ag 205580 10 Remove stepped washer Remove half washers Take off clutch basket Remove needle bearing and supporting...

Page 153: ...9021000 p 289 Hold it using the special tool and pull off the primary gear by turning the screwin Remove the special tools Remove lock ring Takeoff the starter idler gear with the washers Removelock r...

Page 154: ...m locating Qe Remove shift shaft with the washer Remove screw Oo Press locking lever away from shift drum locating and take off the shift drum locating Release the locking lever Remove screw O Take of...

Page 155: ...Remove screws Take off the oil pump cover Remove oil pumpshaft with the internal rotor Remove external rotor Remove screws Take off the oil pump cover Remove oil pumpshaft with the internal rotor Rem...

Page 156: ...Use the drill hole with marking750 Pull off the section of the engine case e Info il Do not tension the section of the engine case The balancer shaft and the main shaft have a stop disk these usually...

Page 157: ...one side Removeshift drum Removeshift forks e iInfo Ensure thatthe pins remain in place Removelockring and the stop disk 305641 10 Remove transmission shafts e Info The stop disk of the countershaft u...

Page 158: ...the crankshaft from the inside to the outside Removeshaft seal rings o of the water pump Press in the shaft seal ring of the crankshaft from the out side to the inside with the open side facingin Inf...

Page 159: ...tighten oil nozzle Q Guideline Oil nozzle for M4 2 Nm 1 5 Ibfft conrod bearing Loctite 243TM lubrication Blow compressedair throughall oil channels and check that theyare clear Position cover plate Mo...

Page 160: ...ne case again Guideline 150 C 302 F Insert the new cold bearings in the bearingseats of the heated section of the engine case if necessary use a Suitable press drift to push them all the way in and ma...

Page 161: ...5 20 Nm 14 8 Ibfft valve plug Position membrane support plate eo with membrane Mount and tighten the screws eal30554810 Guideline Screw mem M3 2 Nm 1 5 Ibf ft branefixation Loctite 243TM e Info i The...

Page 162: ...the balancer shaft Preparatorywork Remove the crankshaft bearinginner ring p 160 Main work Screw suitable screws into the thread Tighten the two screws evenly to pull drive wheel off the crankshaft 17...

Page 163: ...hat oil chan nel is aligned with oil channel If the oil channels are not correctly aligned the conrod bearingwill not be supplied with oil Blow compressed air through the oil channel to checkthatit is...

Page 164: ...ishing work Check the crankshaft run out at the bearingpin p 162 Install the drive wheel of the balancer shaft p 162 Install the crankshaft bearing inner ring p 163 Measure the axial clearance of the...

Page 165: ...ingcrankshaftbearinginner ring i i 1 Main work Fix the crankshaft with special tools and in thevise Separator plate upper part 75029047050 p 290 Separator plate base 75029047051 p 291 Push on the comp...

Page 166: ...g p 160 Calculate the thicknessof the compensation shims Add or remove compensation shims equally on both sides Info li If the axial clearance is too small remove com pensation shims If the axial clea...

Page 167: ...wear NL ve 4 Change the O ring L 9 Check the cylinder bearingsurface for damage wa 1 oO If the cylinderbearingsurface is damaged P Se e Change the cylinderand piston re x Measure the cylinderdiameter...

Page 168: ...is stiff Clean the piston ring groove e Tip ll Use an old piston ring to clean the piston ring groove Check the piston rings for damage If the piston ring is damaged Change the piston ring e Info Moun...

Page 169: ...nce Change the pistonring Mount the piston ring with the markingfacingtoward the pis ton head 17 4 15 Determiningthe piston cylindermounting clearance 305645 10 Check measure the cylinder p 165 Check...

Page 170: ...nal rotor Axial clearance 0 04 0 08 mm 0 0016 0 0031 in If the measured value does not meet specifications Changethe oil pump and if necessary the engine case BO5847 10 Check the internal rotor and ex...

Page 171: ...odecompression spring and then insert the screw through the autodecompression weight The arm of the autodecompression spring 6 is long enough to passright through the autodecompression weight Position...

Page 172: ...ston does not fully withdraw Guideline Thickness of the compensat 2 2 5 mm 0 08 ing disks 0 098in Release the timing chain tensioner Thelatching system locks and the piston stops moving End position o...

Page 173: ...nd wear If there is damage or wear Changethetiming chain guiderail Check timing chain securing guide QO for damage and wear If there is damage or wear Change the timing chain securing guide Check timi...

Page 174: ...ir normal built in position Remove screws ea Screw a suitable screw into the rocker arm shafts Pull out the rocker arm shafts Take off rocker arm 6 17 4 21 Changingthe camshaftbearing Preparatorywork...

Page 175: ...e small camshaft bearing using special tool 86 Internal bearingpuller 15112018100 p 284 Bearing puller 15112017000 p 283 Press in the small camshaft bearingas far as possible using special tool Pressi...

Page 176: ...al and valve spring seat Mark the valves accordingto their normal built in position e Info Place the valves into a box accordingto theinstallation position and label the box 4 Check the run out at the...

Page 177: ...tainer Measure the thickness of the valve spring retainer 2 4 2 5 mm 0 094 0 098in f the measured value does not equalthe specified value Changethevalve spring retainer Valve spring cap thickness Chec...

Page 178: ...27 Installingthe valves Position the valve spring seat Mountthe new valve stem seals Mountvalves Q accordingto their normal built in position Mount valve springs and the spring retainers 305596 10 Pr...

Page 179: ...e and the flat surface must face upward Remove screw 305667 10 Mount andtighten screws Guideline Screw rocker arm M6 12 Nm 8 9 Ibf ft shaft Place shims 6 into the valve spring retainers accordingto th...

Page 180: ...rom the inner clutch hub Removepretension ring and support ring Clean all parts well Check the clutch 9 p 178 4 i 300122 10 17 4 30 Checkingthe clutch Preparatory work Disassemble the antihopping clut...

Page 181: ...r Change the needle bearingand supporting plate Check intermediate clutch discs for damage and wear If the intermediate clutch discs are not level and are pitted Changeall intermediate clutch discs Ch...

Page 182: ...r clutch facingdiscs and intermediate clutch discs alternately Position the release springs Push on the outer clutch hub Qo and pay attention to the markings The arrow of the outer clutch hub must poi...

Page 183: ...tiffness and wear If the bearingsdo not movefreely or are worn Change the bearings Check needle bushing for stiffness and wear If the needle bushing does not movefreely or is worn Change the needle bu...

Page 184: ...drant 0 0315 in If the measured value does not equal the specified value Change thesliding plate 305598 10 17 4 33 Preassemblingthe shift shaft Fix the short end of the shift shaft in a vise Guideline...

Page 185: ...op disk and second gearfixed gear Removethesixth gearidler gear Removethesplit needle bearing o and stop disk 6 Removelock ring e Info Open the lock ring with a screwdriver and twist it off the transm...

Page 186: ...r So and lockring e Info Open the lock ring with a screwdriver and twist it off the transmission shaft with pliers Remove stop disk 7 and third gear idler gear 6 Remove needle bearing and fourth gear...

Page 187: ...Check the shift dogs of idler gears OG sliding gears 6 and fixed gear 6 for damage and wear If there is damage or wear Change the gear wheelpair Checkthetooth faces of idler gears Oo sliding gears 6 a...

Page 188: ...n shaft e Info Use newlock rings with every repair Preparatory work Lubricate all parts carefully before assembling Check the transmission p 184 6 9 306234 10 Main work Secure the main shaft in the vi...

Page 189: ...eve The lock ring engages in the groove of the transmission shaft Push on stop disk andsplit needle bearing Push on sixth gearidler gear with the shift dogs facingdownward Push on second gearfixed gea...

Page 190: ...special tool and push down with sleeve The lock ring engages in the groove of the transmission shaft Mountstop disk Mount needle bearing eo and fourth gear idler gear with the collar facingupward Mou...

Page 191: ...age and wear If there is damageor wear Change the freewheel gear or bearing Check freewheel when removed for damage and wear If there is damage or wear Change the freewheel Check the gear teeth of sta...

Page 192: ...lockwise Remove the freewheel p 190 Turn the freewheel 180 Install the freewheel p 190 17 4 41 Removingfreewheel Extract the lock ring Oo from the groove using suitable pliers 300127 10 Compress the e...

Page 193: ...pliers and checkthatit is seated correctly 17 5 1 Installingthetransmission shafts Clamptheright section of the engine case Holder for engine motor stand 75012001070 p 288 Fitting for work stand 75012...

Page 194: ...hift fork e Info For easier assemblyof middle shift fork liftthe sliding gear of the third fourthgear Mountshift drum Hangtheshift forks into the shift drum Mountshift rail Check the transmission for...

Page 195: ...Grease the shaft seal rings of the balancer shaft Push balancershaft 8 into the bearingseat and remove the special tool Align markings and Mountstop disk Mountthedowels Mount O ring Degrease the seal...

Page 196: ...se M6x25 10 Nm 7 4 Ibf ft e Info Mount the screw with a new copper washer Tighten all screws in a crisscross pattern Guideline Screw engine case M6 10 Nm 7 4 Ibfft 4 17 5 4 Installingthe oil pumps Mou...

Page 197: ...cover Mountandtighten screws Guideline Screw oil pump M5 6 Nm 4 4 Ibf ft cover top Loctite 243TM Mount and tighten screws Guideline Screw oil pump M6 10 Nm 7 4 Ibf ft cover bottom Loctite 243TM Mount...

Page 198: ...ing are not symmetric Release the locking lever Mount and tighten screw e Guideline Screw shift M6 10 Nm 7 4 Ibf ft drum locating Loctite 243TM 4 Slide shift shaft 1 with the washerinto the bearingsea...

Page 199: ...gear Mount the needle bearingand torque limiter o with the washer Mount lock ring Mountthestarter idler gear with the washer Mountlock ring 4 Ensure thatthe woodruff key is seated properly Mountprima...

Page 200: ...h facingdisc is offset by one tooth e Info If necessary turn the main shaft a little to ease access 3 305580 10 Mount the new lock washer with nut Lock the clutch basket and primary gear using special...

Page 201: ...e cap Install and tighten screws with the spring retainers and clutch springs Guideline Screw clutch spring M5 8 Nm 5 9Ibfft e Info Ensurethatall clutch springs have a blue color coding Removespecial...

Page 202: ...ion pulse generator Position the ignition pulse generator Mount screws oO but do not tighten yet Guideline Screw ignition M6 10 Nm 7 4 Ibf ft pulse generator Loctite 243TM Position the cable and posit...

Page 203: ...support bushing into the timing chain securing guide Mount andtighten screws Q Guideline Screw timing M6 10 Nm 7 4 Ibf ft chain guiderail Loctite 2701TM Screw timing M6 10 Nm 7 4 Ibf ft chain tensioni...

Page 204: ...distance Adjustthe distance between the crankshaft position sensor ap and the conductive elementof the rotor using the special tool Guideline Crankshaft position sen sor rotor distance 0 70 mm 0 0276...

Page 205: ...7 4 Ibf ft cover 305556 11 17 5 20 Installing piston 7 Shift the joint of the piston rings by 120 Push the oiled piston into the special tool Piston assembly ring 75029015102 p 288 302600 10 Position...

Page 206: ...haft Mount the piston pin e Info For clarity the following steps are illustrated using a disassembled piston Position the piston pin retainer 400366 10 Insert the special tool and firmly press it towa...

Page 207: ...nderhead Mount and tighten screws eh with the washers Guideline Cylinderhead M10 Tightening sequence screw Tighten diagonally beginningwith the rear screw on the timing chain shaft Step 1 15 Nm 11 1 I...

Page 208: ...camshaft and the drill hole Oo cylinder head are aligned Position the camshaft support plate Mount and tighten screw Guideline Screw camshaft support plate Mex12 10 Nm 7 4 Ibf ft Loctite 243TM Marking...

Page 209: ...ovespecialtool Crank the engine several times Set the engine to ignition top dead center p 143 Check the valve clearance on all valves between the valve and the rocker arm using the special tool Guide...

Page 210: ...dingto the instal lation position Correct the shims as indicated by the results of the valve clear ance check Insert suitable shims Position the rocker arms and mount the rocker arm shafts The tapped...

Page 211: ...bf ft 17 5 27 Installingthethermostat 17 5 28 Installingthe oil filter P 305527 10 Spark plug wrench 75029172000 p 293 4 Position thermostat a with the gasket Drill hole must face upward Position the...

Page 212: ...e O ring Y Pin engagesin drill hole Mount and tighten screws with the washers Guideline Screw gear sen M5 5 Nm 3 7 Ibf ft sor Loctite 243TM 4 Before mounting grease spacer in area and O ring Long life...

Page 213: ...10 Nm 7 4 Ibf ft cover Mount andtighten screw 6 Guideline Screw alterna M6 10 Nm 7 4 Ibf ft tor cover chain Loctite 243TM shaft through hole Push the oil screen with O rings on to a pin wrench Push th...

Page 214: ...Nm 11 1 Ibfft 4 Grease the O ring and mount the starter motor Long life grease p 280 Mount and tighten oil throttle 0 Guideline Screw starter M6 10 Nm 7 4 Ibf ft motorwith oil Loctite 243TM throttle 4...

Page 215: ...ents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasingwear of the clutch facingdiscs Never use DOT 5 brakefluid It is silicone base...

Page 216: ...t is silicone basedand purple in color Oil seals and clutch lines are not designed for DOT 5 brakefluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean bra...

Page 217: ...e Info Clean up overflowed or spilled brake fluid immediately with water 215...

Page 218: ...Remove the cabletie s Expose the cable Remove screws 6 with the washers Take off the gear position sensor aN Lubricate O ring 6 of the new gearposition sensor 3 Position the gear position sensor Pin e...

Page 219: ...25 Nm 18 4 Ibfft chassis Finishing work Program the gear position sensor p 217 Remove the motorcycle from thelift stand p 12 Condition The diagnostics tool is connected and running Preparatory work R...

Page 220: ...in Rinse eyes thoroughlywith water and consult a doctor immediatelyif coolant gets into the eyes Change clothingif coolant spillsonto your clothing Preparatorywork Remove the engine guard p 39 Main wo...

Page 221: ...textractionsystem when starting or runningtheengine in an enclosed space Start the engine and run it until the 5th bar of the temperature indicator lights up Stop the engine and allow it to cool down...

Page 222: ...tank oO Check the antifreeze in the coolant 25 4 49 C HLS aus 49 FR If the antifreeze in the coolant does not match the speci fied value Correct the antifreeze in the coolant Check the coolant level i...

Page 223: ...hing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediatelywith plenty of water in the event of contact with the skin Rinse eyes thoroughlywith water and consult a do...

Page 224: ...ard Keep coolant out of the reach of children Do not allow coolant to comeinto contact with the skin the eyes and clothing Consult a doctor immediatelyif coolant is swallowed Rinse the affected area i...

Page 225: ...nsatingtank Danger Dangerofpoisoning Exhaustgases are toxicand inhal ingthemmay result in unconsciousnessand death Always make sure thereis sufficientventilation when runningtheengine Use an effective...

Page 226: ...ter Oil pressure regulator valve Timing chain tensioner Oil nozzle for rocker arm lubrication Transmission Clutch Oil nozzle for piston cooling Oil filter Oil nozzle for conrod bearing lubrication Oil...

Page 227: ...oil level viewer 802208 10 as If the engine oil level is not at the specified level Add engine oil p 231 _ Warning Danger of scalding Engine and gearoil get very hot when the motorcycle is ridden Wea...

Page 228: ...ning the engine in an enclosed space Start the engine and let it warm up Checktheengine oil pressure Engine oil pressure Coolant temperature 2 0 4 bar 2 6 psi 2 70 C 2 158 F Engine speed 1 500 rpm Coo...

Page 229: ...he event of scalding rinse the area affected immediatelywith lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Disposeofoils grease filters fuel cleaning agen...

Page 230: ...l hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatorywork...

Page 231: ...ding rinse the area affected immediatelywith lukewarm water Warning ae Environmental hazard Hazardous substances cause environmental damage Disposeofoils grease filters fuel cleaning agents brake flui...

Page 232: ...with O ring Oo from the clutch cover and add engineoil Engineoil 1 70 Engineoil 1 8 qt SAE 10W 60 00062010035 p 278 Engine oil Engine oil Alternative engineoil SAE 10W 50 p 279 Refit plug with O ring...

Page 233: ...h engine oil Engine oil SAE 10W 60 00062010035 p 278 Engine oil SAE 1OW 50 4 p 279 e Info i In order to achieveoptimal engine performance it is not advisable to mix different engineoils We recommended...

Page 234: ...tor winding resistance 0 15 0 30Q at 20 C 68 F If the indicated value does not correspondto the setpoint value Changethestator Stator winding measurementIll check the resistance Measure the resistance...

Page 235: ...round Resistance aQ If the indicated value does not correspond to the setpoint value Changethestator Stator winding measurement check the voltage EN Measure the voltage betweenthespecified points V St...

Page 236: ...e stator 250 V winding at 4000 rpm 20 C 68 F If the indicated value does not correspondto the setpoint value Changethestator 600851 10 Preparatorywork Remove the seat p 73 Take off the side cover p 73...

Page 237: ...Ignition coil Resistance of primary 1 105 1 4950 winding at 20 C 68 F If the displayed value does not correspond to specifica tions Change the ignition coil 235...

Page 238: ...ant temperature 25 C77 F Let the engineidle for at least 10 minutes 600 seconds e Info Do not activate the throttlegrip during the initialization process Switch off the ignition after 10 minutes 600 s...

Page 239: ...tion Semi dry sump lubrication system with two rotor pumps Primary transmission 36 79 Clutch APTCTM antihopping clutch in oil bath hydraulically operated Transmission 6 gear claw shifted Transmissionr...

Page 240: ...Piston diameter Size 101 955 101 965 mm 4 01397 4 01436 in Size II 101 965 101 975 mm 4 01436 4 01476in Piston cylinder mounting clearance New condition 0 035 0 060 mm 0 00138 0 00236in Wearlimit 0 1...

Page 241: ...on After the vehicle is run in 0 7 1 1 000 km s 0 7 qt 600 mi e Info The oil consumption depends ontheriding style and on the operating conditions Screw membranefixation M3 2 Nm 1 5 Ibf ft Loctite 243...

Page 242: ...mp cover bottom M6 10 Nm 7 4 Ibf ft Loctite 243TM Screw rocker arm shaft M6 12 Nm 8 9 Ibf ft Screw shift drum locating M6 10 Nm 7 4 Ibf ft Loctite 243TM Screw shift lever M6 14 Nm 10 3 Ibf ft Loctite...

Page 243: ...plug outside M10x1 11 Nm 8 1 Ibf ft Spark plug inside M12x1 25 18 Nm 13 3 Ibf ft Coolant temperature sensor on M12x1 5 12 Nm 8 9 Ibf ft cylinder head Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf...

Page 244: ...rmance Systems 4618 with Pro Lever linkage Suspension travel front 250 mm 9 84 in rear 250 mm 9 84 in Brake system front Disc brake with dual piston brake caliper floating rear Disc brake with single...

Page 245: ...W5W socket W2 1x9 5d 12V 5W Instrumentlights and indicator LED lamps Turn signal 690 Enduro R EU R10W socket BAL5s 12V 10 W Turn signal 690 Enduro R US RY1OW socket BAU15s 12V 10 W Brake tail light 6...

Page 246: ...35 24 in Fork oil per fork leg 635 ml 21 47fl 0z Fork oil SAE 4 4860116681 E28 p 279 Shock absorberarticle number 15 18 7L 10 Shock absorber WPPerformance Systems 4618 with Pro Lever linkage Compressi...

Page 247: ...e holder on M5 4 Nm 3 Ibf ft swingarm Screw cable on starter motor M5 3 Nm 2 2 I bf ft Screw electrical holder M5 3 Nm 2 2 Ibfft Screw exhaust heat shield M5 8 Nm 5 9 Ibfft Loctite 243TM Screw fuel ho...

Page 248: ...ft Screw wheel speed sensor M6 6 Nm 4 4 Ibf ft Nut rear sprocket screw M8 35 Nm 25 8 Ibf ft Loctite 2701TM Remaining nuts chassis M8 25 Nm 18 4 Ibfft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Scre...

Page 249: ...33 2 Ibf ft Screw bottom shock absorber M10 45 Nm 33 2 Ibf ft Loctite 243TM Screw engine bearer on frame M10 45 Nm 33 2 Ibf ft Screw handlebar support M10 40 Nm 29 5 Ibfft Loctite 243TM Screw side st...

Page 250: ...hine on the motorcycle during cleaning Seal the exhaust system to keep water out First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner...

Page 251: ...n steering lock Universal oil spray p 281 e Info If you use the motorcycle in winter you must expect salt on the roads You should therefore take precau tions against aggressive road salt If the vehicl...

Page 252: ...Clean the chain p 96 250...

Page 253: ...eens OVO een Check the antifreeze and coolantlevel p 219 401058 01 Checkthetire air pressure p 84 Removethe battery p 99 Recharge the battery Guideline Storage temperature of bat 0 35 C 32 95 F tery w...

Page 254: ...059 01 Removethe motorcycle from the lift stand p 12 Recharge the battery Install the battery p 100 Set the clock p 125 Perform checks and maintenance measures whenpreparing for use Take a test ride 2...

Page 255: ...nt brake fluid 9 p 116 Changetherear brakefluid p 123 Change the hydraulicclutch fluid p 214 Check the brakefluid level of the front brake p 114 Checkthe rear brake fluid level p 121 Check correct the...

Page 256: ...in the Service and ManufacturerWar ranty Booklet One time interval e Periodic interval after every sporting use Every year every 10 000 km 6 200mi Check the frame Check the swingarm Check the swingar...

Page 257: ...255...

Page 258: ...ad wird wtides i281 _ y 1 f thd p 12 C1 E e z z c X19 x119 ee AFI O 4 i M10 GIF Ty 20 G20 Ki FT ser1 crt a x292 X291 4 EBI4 Ful2 X19 X119 5 3 5 2 3 i 5 L_ L__ a x302 x301 E i 11 F1 i i2Fi F Ki 690 End...

Page 259: ...tronics control unit Fuse Battery Alternator Starter relay with main fuse Start auxiliaryrelay Electric starter system Voltage regulator Connector for accessory ground terminal 31 ACC 1 not assigned C...

Page 260: ...izv ziAg aif dj pidge ob pgaje ard PE E_E PAD 1 sie wove L f KG EC L zs ELIN ei Oey 45 Lis ba vIAD 2 2 4 rarveles CITA jrs piG3ie bs rian BEX OZLX SLX PLX PiAd L2Lx osx gS ee 2 nm 5 were wht were yor...

Page 261: ...K12 K30 M13 P10 11 23 X295 Engine electronics control unit Fuse Fuse Light relay Powerrelay Fuel pump Combinationinstrument Ignition and steering lock Emergency OFF switch electric starter button Diag...

Page 262: ...c X122 X126 mn X64 X66 Fui2 Fula 1 BW 3 bi2 FS 6 X61 E13 P35 X62 BP 4 DGI4 DG 4 ep X62 X61 Fsl2 Ful2 Bwi3 B2 X122 X126 X64 X66 5 Z 2 25 I 5 g E ea 4 yetu yetu yebuen 4 F1 f2 F8 dbo br br br br br br...

Page 263: ...Components EIS FS F6 P10 PLS P35 24 Low beam high beam Fuse Fuse Combinationinstrument Horn Parking light Light switch horn button high beam flasher button turn signal switch 261...

Page 264: ...et dace X34 B76 e J dA X32 AK 2 AHI2 X26 q f Ba 3 FB hE ye be yebu yetu BGI3 AdI3 K132 or cw CWI2 X63 3 FB aber or br br br or yetu th 5 F1 or be br br brory Set 690 EnduroR 2017 2018 4 11 ROO346 01 l...

Page 265: ...Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp P36 Brake tail light 263...

Page 266: ...cxi2 cxi2 Cxi2 haan E 2 a y J cwi2 cwi2 cwi2 cwi2 K20 24 P42 PAt x71 P4G P45 13 03 tolovis a FRI4 y 1 cwi2 cwi2 x70 cwi2 owe Bs E a X29 BT 3 ACXI2 oA CX 2 CX 2 ow CXI2 X23 X30 X31 X58 B 3 5 5 Bae 5 5...

Page 267: ...1 P42 P45 P46 24 Turn signal relay Combinationinstrument Turn signal front left Turn signal front right Turn signal rear left Turn signal rear right Light switch horn button high beam flasher button t...

Page 268: ...B83 o f 11 81 a S X110 c X129 X128 IDI2 X33 Ful2 FIZ AVI2 a a Bi 2 Fa F4 M14 B33 CRI cRM X294 X293 y Bil2 fe Ful2 Fui2 AVI2 X129 X128 ID 2 X33 5 X110 x E 5 5 Ld E 6 8 i OFT F Ki 690 EnduroR 2017 2018...

Page 269: ...ts B33 Radiator fan temperature switch F4 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 assig...

Page 270: ...t x1 geass 33 i z 3 z y 1 cB fo te 5 EREEE 53 23 i z 2 2 x35 X127 X36 1 1 1 BHIE X16 X103 X40 X43 Ful2 117 177 GHG U asi2 a2 DFI2 parz BREEEEL dd dpe 4 2 M60 B80 R51 1 R51 2 M20 M51 2 01 9 2 2 ey oO o...

Page 271: ...20 M51 M60 R51 1 R51 2 Engine electronics control unit Throttle grip Fuse Evaporate emission control valve optional Injection valve cylinder 1 Throttle stepper motor Ignition coil 1 cylinder 1 Ignitio...

Page 272: ...EDI32 qs QEDIB2 KA x1 x x1 x1 X2 X20 X2 Zz 8 z z g z 5 23 B Tr OtC Yd a z 2 2 z fe X45 X54 CUl4 ALI2 X37 X55 XST I cm wie 4 7ECI3 _DYi4 ATi2 B51 B38 B12 855 B21 N DYI4 ATI2 Y 1 cmi2 pvi2 ECI3 QD CUI4...

Page 273: ...B38 B51 P10 37 55 Engine electronics control unit Intake air temperature sensor Coolant temperature sensor cylinder 1 Oil pressure sensor Clutch switch Lambdasensor cylinder 1 Combinationinstrument Sw...

Page 274: ...GFI48 GFi48 GFI48 x1 xt x1 x x1 x x1 a 2 e F z 2 g a E x49 X24 B3 X51 X53 xi Mi4 APIE DPI3 SDX 3 AMI3 Bee q Dyi4 B30 B26 B13 Bat B34 al il AMI3 4 4 pyi4 API DP IDxI3 1B 3 X51 X53 x111 4IMi4 X49 X24 a...

Page 275: ...ll B13 B26 B30 B34 B41 P10 Engine electronics control unit Ambientair pressure sensor Rollover sensor Side stand sensor Gear position sensor Induction manifold pressure sensor cylinder 1 Combinationin...

Page 276: ...A6 M1 A1 a 11 43 a We A 5 GF 48 GFi48 GFI48 sf SEDa2 ED 32 x1 x1 x1 X2 X2 a fi s Es SEs z 2 ai 5 X52 X56 4 aui2 we ATI2 IKI2 B37 B32 a IKI2 Ww2 X56 55 5 5 5 6A io bdFt ROO352 01 690 EnduroR 2017 2018...

Page 277: ...Components All B32 B37 P10 Engine electronics control unit Fuel level sensor Crankshaft position sensor Combinationinstrument 275...

Page 278: ...83 gsi 22 B 5 e Bs zs L L__1 6 68 o mn 33 fiz 5 2 BS E 5 2 Fos 2 c Vy X42 X39 X125 K124 X123 DMZ DMI2 sFUl2 EA2 EA2 LA x 2 2 I Fu2 caFU2 F9 X295 F24 22 B70 B74 _ 4 API I x x O X303 iT Fie EW2 EN2 a X...

Page 279: ...trol unit ABScontrol unit Front wheel speed sensor Rear wheel speed sensor Fuse ABSfuse ABSfuse Combinationinstrument Diagnostics connector Cable colors bl br bu gn er Ibu or pk pu rd wh ye Black Brow...

Page 280: ...thatcomplies with the requirements stated see specificationson the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the...

Page 281: ...specificationson the container and thatexhibit the corresponding properties Standard classification SAE p 301 SAE 2 5 Guideline Use only oils that comply with the specified standards see specificatio...

Page 282: ...er Motorex Bike Grease 2000 Recommended supplier WPPerformance Systems WPRacingGrease IPR 2 Recommended supplier Bel Ray MC 11 Recommended supplier Lubcon Turmogrease PP 300 Recommendedsupplier Molyko...

Page 283: ...Recommended supplier Motorex Moto Polish Shine Recommended supplier Motorex Moto Protect Recommendedsupplier Motorex Quick Cleaner Recommended supplier Motorex Joker 440 Synthetic 281...

Page 284: ...029013100 HOO518 01 Li eae HO1065 01 Art no 00029013004 Art no 00029013015 Art no 00029013100 Art no 00029095050 Feature EU safety plug Nominal voltage 230 V Mains fuse 16A Powercable length 5 m 16 ft...

Page 285: ...Art no 00029095052 Feature UK safety plug approx Nominal voltage 230 V Mains fuse 16A Powercable length 5 m 16 ft approx Charger cable length 5 m 16ft SAS HO1065 01 Art no 00029095053 Feature CH plug...

Page 286: ...HOO565 01 Art no 15112018100 A Feature 18 23 mm 0 71 0 91in 15112018100 HO00522 01 AA Art no 50329050000 50329050000 51012011000 HO0572 01 58429009000 H00593 01 Art no 51012011000 Art no 58429009000...

Page 287: ...Inside diameter 43 9 mm 1 728 in 58429037043 HOO598 01 A Art no 58529005000 58529005000 HOO608 01 Art no 59029019000 2x A 59029019000 HO0610 01 Art no 59029026006 A Feature Diameter 6 05 mm 0 2382in...

Page 288: ...01 Art no 59029033000 59029033000 H00613 01 Art no 59029041100 A Feature 5 piece 0 10 0 25 mm 0 0039 0 0098in 59029041100 60029057000 HO0650 01 60029057100 H00651 01 Art no 60029057000 Art no 60029057...

Page 289: ...ZA A 61029093000 HOO659 01 Ad 61029094000 HOO660 01 Art no 61029093000 Art no 61029094000 61229001000 HO0662 01 62529055100 HG0693 01 Art no 61229001000 Art no 62529055100 287...

Page 290: ...0 H00703 01 75012001070 HOO704 01 HO00706 01 Art no 75012001060 Art no 75012001070 Art no 75029005000 75029005000 HOO705 01 Art no 75029015102 A Feature Height 45 mm 1 77 in Diameter 102 mm 4 02 in 75...

Page 291: ...A Art no 75029021000 75029021000 H00707 01 Art no 75029033000 AX 75029033000 HO0708 01 75029035000 H00710 01 75029036000 HOO711 01 Art no 75029035000 Art no 75029036000 289...

Page 292: ...Art no 75029044010 H00714 01 75029047050 H00715 01 Ad 75029044010 HOO0712 01 A Art no 75029044020 75029044020 HOO713 01 Art no 75029047000 oS 75029047000 Art no 75029047050 290...

Page 293: ...75029047051 HO0716 01 75029048100 HO0718 01 Art no 75029047051 Art no 75029048100 bes cy 75029050000 H00719 01 75029051000 HOO0721 01 Art no 75029050000 Art no 75029051000 291...

Page 294: ...Art no 75029055000 75029055000 HOO722 01 Art no 75029080000 A 75029080000 HOO723 01 Art no 75029080050 A 75029080050 HO0724 01 Art no 75029081000 A 75029081000 HOO725 01...

Page 295: ...5029090000 HO0726 01 Art no 75029091000 75029091000 HOO727 01 Art no 75029172000 A Feature Drive 1 2 in Hexagonalpart 14 mm 0 55in Length 85 mm 3 35 in 75029172000 HO0729 01 Art no 77329006000 A 77329...

Page 296: ...oF 77329010000 Art no 77329010000 00029196000DE HO1112 01 HOO765 01 A Art no 77329051000 77329051000 HOO771 01 Art no 78029060000 78029060000 HOO795 01 Art no 000291 96000DE 294...

Page 297: ...Art no 00029196000EN 00029196000EN HO1113 01 Art no O0029196000ES 00029196000ES HO1117 01 Art no 00029196000FR 00029196000FR HO1116 01 Art no 00029196000IT 000291 96000IT HO1115 01 295...

Page 298: ...JP HO1118 01 00029196000US HO1114 01 Art no O0029196000JP Art no O00029196000US T103 H00838 01 H00841 01 Art no T103 Feature adjustable Diameter 4 mm 0 16in Art no TLO6S Feature Diameter 68 75 mm 2 68...

Page 299: ...2 Art no T107S T107S HO0842 01 Art no T1120 A Feature Z Diameter 8mm 0 31in T120 HOO844 01 Art no T1206 A Feature Diameter 15 30 mm 0 59 1 18 in 71206 HOO0880 01 Art no T1207S AA 712078 HO00881 01 297...

Page 300: ...0S HOO890 01 Art no T129 A Feature 6 Diameter 15 30 mm 0 59 1 18in T129 HOO846 01 Art no T1401 A Feature cS Diameter 48 mm 1 89 in T1401 HO0894 01 Art no T14026S1 A Feature M12 Diameter 17 mm 0 67in T...

Page 301: ...T14032 HOO920 01 Art no T1403S 2x A Feature Diameter 48 mm 1 89 in z Diameter 60 mm 2 36 in T1403S HOO896 01 Art no T14040S Ad Feature ie Diameter 48 mm 1 89 in T14040S HOO922 01 Art no T1515 A Featur...

Page 302: ...Art no T170S1 2x A 3x A dvd 1717081 HOO0855 01 300...

Page 303: ...are demanded for automobileengines the focus for motorcycle engines is on high performanceat high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the sameoil...

Page 304: ...ty system that prevents locking of the wheels when driving straight ahead withoutthe influenceof lateral forces PA Preload adjuster Device on the spring elements which enables adjust mentof the spring...

Page 305: ...Art no Article number ca circa cf compare e g for example etc et cetera ia inter alia no number poss possibly 303...

Page 306: ...ay aes cuscerernnererermmmewe ene 102 TETHOVINS os cs nO He siereremrmeRENeeRE Ey Hes 99 Brake disc front brake changing 0005 89 of rear brake changing 0005 92 Brake discs checking OS 83 RS SS HA OG E...

Page 307: ...rkingmn the individual parts timing chain and timing chain sprocket clutch checking Freee ee ee ee os 178 FEMOVINE oe eee eee eee eee uees 147 countershaft assembling 187 timing chain rails removing 1...

Page 308: ...ee 18 YEMOVE wy 6 FS Bh EN Sale abE oe ee 18 Front wheel INStANINE ss cee wee aes weceeesraeeeemcoe eee oes 88 FEMOVINE a we ws a eee ete ON oe 87 Fuelfilter EVANS x m0 ae ne Ws Ae wR ees 77 Fuel pres...

Page 309: ...wcvisiee ew Oe we ee eee 42 Shock absorber article number 11 Side cover WIGUNENE 6 xs systems eH oe Ko aT TF 74 fEMGVING oa as scien OH He wen CET O 73 Spare parts 2 0 0 ee ee ee 9 Spoketension QNeCKI...

Page 310: ...Page 09 of Tl 6 ey es cemeEReeee AG 272 Page 1Oof Tle eh 8s erie ae 274 Page LT Of TL 4 Bi SESS Se SS FSG 276 Worries sc ea wai su wa scomannaricawanaaim ae ee 8 308...

Page 311: ...READY TO RACE www ktm com 3206323en 09 2017 KTM Sportmotorcycle GmbH a 5230 Mattighofen Austria gcd sphce LT Photo Mitterbauer KTM hittp www ktm com ae...

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KTM 690 Enduro R 2018, Repair Manual

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Summary of Contents for 690 Enduro R 2018

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