KTM 690 Enduro R AUS/UK 2012, Руководство по ремонту

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TABLE OF CONTENTS
3
13.7.8 Checking the chain, rear sprocket, engine
sprocket, and chain guide............................ 78
13.7.9 Cleaning the chain ...................................... 80
13.7.10 Checking the rear hub rubber dampers.......... 80
14 WIRING HARNESS, BATTERY..................................... 82
14.1 Removing the battery ...................................... 82
14.2 Installing the battery ....................................... 82
14.3 Disconnecting the battery ................................ 82
14.4 Connecting the battery .................................... 83
14.5 Recharging the battery .................................... 83
14.6 Checking the charging voltage .......................... 84
14.7 Changing the main fuse................................... 85
14.8 Changing fuses of individual power
consumers...................................................... 85
14.9 Adjusting the engine characteristic ................... 86
15 BRAKE SYSTEM ........................................................ 88
15.1 Checking the front brake linings ....................... 88
15.2 Changing the front brake linings ....................... 88
15.3 Checking the free travel of the hand brake
lever .............................................................. 90
15.4 Adjusting the free travel of the hand brake
lever .............................................................. 90
15.5 Checking the front brake fluid level .................. 90
15.6 Adding front brake fluid................................... 91
15.7 Changing the front brake fluid.......................... 91
15.8 Checking the rear brake linings ........................ 93
15.9 Changing the rear brake linings ........................ 93
15.10 Checking the free travel of foot brake lever ........ 94
15.11 Adjusting the basic position of the foot brake
lever .............................................................. 95
15.12 Checking rear brake fluid level ......................... 95
15.13 Adding rear brake fluid .................................... 96
15.14 Changing the rear brake fluid ........................... 96
16 LIGHTING SYSTEM, INSTRUMENTS ........................... 98
16.1 Combination instrument .................................. 98
16.1.1 Setting kilometers or miles .......................... 98
16.1.2 Setting the clock ........................................ 98
16.1.3 Setting/resetting display TRIP 1 ................... 98
16.1.4 Setting/resetting display TRIP 2 ................... 98
16.1.5 Setting the wheel circumference .................. 99
16.2 Checking the headlight setting ....................... 100
16.3 Adjusting the headlight range......................... 100
16.4 Removing the headlight mask with the
headlight...................................................... 100
16.5 Installing the headlight mask with the
headlight...................................................... 101
16.6 Changing the parking light bulb...................... 101
16.7 Changing the headlight bulb .......................... 102
16.8 Changing the turn signal bulb ........................ 102
17 ENGINE .................................................................. 104
17.1 Removing the engine..................................... 104
17.2 Installing the engine...................................... 106
17.3 Engine disassembly....................................... 110
17.3.1 Clamping the engine into the engine
assembly stand......................................... 110
17.3.2 Draining the engine oil .............................. 110
17.3.3 Removing starter motor ............................. 111
17.3.4 Removing valve cover ................................ 111
17.3.5 Removing the alternator cover .................... 111
17.3.6 Removing spacer ...................................... 111
17.3.7 Removing gear position sensor ................... 111
17.3.8 Removing oil filter .................................... 112
17.3.9 Removing thermostat ................................ 112
17.3.10 Setting engine to ignition top dead center ... 112
17.3.11 Removing water pump wheel...................... 113
17.3.12 Removing clutch cover .............................. 113
17.3.13 Removing spacer and spring ...................... 114
17.3.14 Removing spark plug................................. 114
17.3.15 Removing timing chain tensioner................ 114
17.3.16 Removing camshafts ................................. 114
17.3.17 Removing cylinder head ............................ 115
17.3.18 Removing piston ....................................... 115
17.3.19 Removing rotor ......................................... 115
17.3.20 Removing timing chain rails....................... 116
17.3.21 Removing timing chain and timing chain
sprocket................................................... 116
17.3.22 Removing crankshaft position sensor .......... 117
17.3.23 Removing clutch cage ............................... 117
17.3.24 Removing primary gear .............................. 118
17.3.25 Removing starter drive............................... 118
17.3.26 Removing shift shaft ................................. 119
17.3.27 Removing shift drum locating..................... 119
17.3.28 Removing locking lever.............................. 119
17.3.29 Removing oil pumps.................................. 119
17.3.30 Removing left engine case ......................... 120
17.3.31 Removing crankshaft and balancer shaft ..... 120
17.3.32 Removing transmission shafts .................... 121
17.4
Work on individual parts ................................ 122
17.4.1 Work on the right section of the engine
case ........................................................ 122
17.4.2 Work on the left section of the engine
case ........................................................ 123
17.4.3 Work on the clutch cover ........................... 125
17.4.4 Removing crankshaft bearing inner ring ...... 125
17.4.5 Removing balancer shaft drive wheel .......... 125
17.4.6 Changing the connecting rod, conrod
bearing, and crank pin .............................. 125
17.4.7 Checking crankshaft run-out at bearing
pin .......................................................... 127
17.4.8 Installing balancer shaft drive wheel ........... 127
17.4.9 Installing crankshaft bearing inner ring ....... 128
17.4.10 Measuring axial clearance of crankshaft
and balancer shaft .................................... 128
17.4.11 Cylinder - Nikasil
®
coating ......................... 129
17.4.12 Checking/measuring the cylinder ................ 129
17.4.13 Checking/measuring the piston................... 130
17.4.14 Checking piston ring end gap ..................... 131
17.4.15 Checking piston/cylinder mounting
clearance ................................................. 131
17.4.16 Checking oil pumps for wear ...................... 131
17.4.17 Replacing autodecompressor...................... 132
17.4.18 Preparing timing chain tensioner for
installation............................................... 132
17.4.19 Checking timing assembly ......................... 133
17.4.20 Removing rocker arm ................................ 133
17.4.21 Changing camshaft bearing........................ 134
17.4.22 Removing valves ....................................... 135
17.4.23 Checking valves ........................................ 135
17.4.24 Checking valve springs .............................. 136
17.4.25 Checking valve spring retainer.................... 136
17.4.26 Checking cylinder head ............................. 136
17.4.27 Installing valves........................................ 137
17.4.28 Installing rocker arm ................................. 137
17.4.29 Disassembling the antihopping clutch......... 138