KTM 690 enduro R EU Repair Manual
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KTM 690 enduro R EU Repair Manual

2011
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REPAIR MANUAL
2011
690 Enduro R EU
690 Enduro R AUS/UK
690 Enduro R USA
Art. no. 3206121en

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Summary of Contents for KTM 690 enduro R EU

  • Page 1 REPAIR MANUAL 2011 690 Enduro R EU 690 Enduro R AUS/UK 690 Enduro R USA Art. no. 3206121en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Adjusting the rebound damping of the shock TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 absorber............38 Symbols used ........... 5 Measuring the unloaded rear wheel sag ..... 38 Formats used............ 5 Checking the static sag of the shock absorber ..38 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 13.7.8 Checking the chain, rear sprocket, engine 17.3.9 Removing thermostat ........ 114 sprocket, and chain guide......80 17.3.10 Setting engine to ignition top dead center ... 114 13.7.9 Cleaning the chain ........82 17.3.11 Removing water pump wheel...... 115 13.7.10 Checking the rear hub rubber dampers..
  • Page 6 TABLE OF CONTENTS 17.4.30 Checking the clutch ........139 20 LUBRICATION SYSTEM..........170 17.4.31 Preassembling the antihopping clutch..141 20.1 Oil circuit............. 170 17.4.32 Checking shift mechanism......142 20.2 Checking the engine oil level......170 17.4.33 Preassembling shift shaft ......142 20.3 Checking the engine oil pressure ....

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

  • Page 8: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

  • Page 9: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 101045-10 Type label Type label is located on the upper right frame tube below the seat. 101046-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 11: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is on the left of the shock absorber. 101048-10...

  • Page 12: Motorcycle

    MOTORCYCLE Raising the motorcycle with 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. – Raise the motorcycle using the underride guard under the motorcycle. The wheels must no longer touch the ground.

  • Page 13: Removing The Motorcycle From The Work Stand

    MOTORCYCLE Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the work stand and lean the vehicle on the side stand. 300201-10 –...

  • Page 14: Starting The Motorcycle To Make Checks

    MOTORCYCLE Info Do not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

  • Page 15: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise until they stop. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

  • Page 16: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Loosen the fork protection. ( p. 14) Main work – Push dust boot of both fork legs downwards. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes.

  • Page 17: Removing Fork Legs

    FORK, TRIPLE CLAMP Removing fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Tie the rear of the vehicle down. Main work – Remove screws – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.

  • Page 18: Installing The Fork Legs

    FORK, TRIPLE CLAMP – Remove screws . Remove the fork protector from above. 201337-10 Installing the fork legs – Slide on the fork protector from above and position it. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 201337-11 –...

  • Page 19: Servicing The Fork

    FORK, TRIPLE CLAMP 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. – Clean screw and the wheel spindle.

  • Page 20: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP 6.10 Disassembling the fork legs Info The steps are identical for both fork legs. Condition The fork legs are disassembled. – Note down the present state of rebound damping and compression damping – Completely open the adjusters of the rebound and compression damping. 201470-10 –...
  • Page 21 FORK, TRIPLE CLAMP – Clamp the special tool in the vise. Loosen screw cover 200647-12 – Remove screw cover with preload spacers – Remove adjusting tube 200648-12 – Pull the spring down. Remove the special tool. – Remove the spring. 200649-01 –...
  • Page 22 FORK, TRIPLE CLAMP – Remove the cartridge. 200653-01 – Remove dust boot 200735-10 – Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied. 200656-01 – Warm up the outer tube in area of the lower sliding bushings.

  • Page 23: Disassembling The Cartridge

    FORK, TRIPLE CLAMP 6.11 Disassembling the cartridge Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p. 18) Main work – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p.

  • Page 24: Disassembling The Tap Compression

    FORK, TRIPLE CLAMP – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 226) 200697-10 – Remove nut – Remove shim stack completely. 200698-11 – Remove the piston. – Completely remove shim stack 200699-11 –...

  • Page 25: Checking The Fork Legs

    FORK, TRIPLE CLAMP Main work – Clamp the tap compression in a bench vise using soft jaws. – Remove nut – Remove the spring. – Remove washer 201482-10 – Remove piston – Remove shim stack 201483-10 – Extract the tap compression. –...

  • Page 26: Assembling The Tap Compression

    FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Run-out of inner tube » If the measured value is greater than the specified value: – Replace the inner tube. 200685-10 – Check the outer tube for damage. »...

  • Page 27: Assembling The Cartridge

    FORK, TRIPLE CLAMP – Clamp the tap compression in a bench vise using soft jaws. – Mount shim stack Info Mount the smaller shims below. – Mount pistons with O-ring. Info The side with the largest inside diameter faces upward. 201485-10 –...
  • Page 28 FORK, TRIPLE CLAMP – Mount piston with the piston ring. Info The side with the largest inside diameter faces downward. – Mount shim stack Info Align the triangular plate exactly with the piston opening. – Mount and tighten nut Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft)

  • Page 29: Assembling The Fork Legs

    FORK, TRIPLE CLAMP – Screw on fluid barrier as far as it will go. Info The fluid barrier must be tightened as much as possible. Do not use tools. 200746-12 6.16 Assembling the fork legs Info The steps are identical for both fork legs. Preparatory work –...
  • Page 30 FORK, TRIPLE CLAMP – Push on the lower sliding bushing – Mount the upper sliding bushing Info Without using a tool, carefully pull the stack apart by hand. 200671-10 – Heat up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) –...
  • Page 31 FORK, TRIPLE CLAMP Info The special tool must be used to prevent the adjusting tube from being lifted and thus to prevent oil from reaching the piston rod. – Lubricate the O-ring. Lubricant (T158) ( p. 214) – Mount and tighten compression adjuster Guideline Compression adjuster M14x1...
  • Page 32 FORK, TRIPLE CLAMP – Clamp the special tool in the vise. – Grease the thread of the piston rod. Lubricant (T159) ( p. 214) – Grease the upper edge of the piston rod. Lubricant (T158) ( p. 214) – Screw the screw cover with the preload spacers on to the piston rod. Info 201477-10 The screw cover must be screwed to the stop before the piston rod starts...

  • Page 33: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
  • Page 34 FORK, TRIPLE CLAMP Guideline Screw, steering stem 20 Nm (14.8 lbf ft) Finishing work – Check the steering head bearing play. ( p. 31) – Remove the motorcycle from the lift stand. ( p. 10)

  • Page 35: Handlebar, Controls

    HANDLEBAR, CONTROLS Handlebar position On the upper triple clamp, there are 2 holes at a distance to each other. Distance between holes 15 mm (0.59 in) The holes on the handlebar support are placed at a distance from the center. 0 0 A Distance between holes...

  • Page 36: Checking The Play In The Throttle Cable

    Main work – 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...
  • Page 37 HANDLEBAR, CONTROLS – Tighten counter nut...

  • Page 38: Frame

    FRAME Removing the engine guard – Remove screws on the left and right. – Pull the engine guard forward out of the holders and set it down. 306810-10 Installing the engine guard – Slide the engine guard into holders at the rear. –...

  • Page 39: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. –...

  • Page 40: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Caution 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. – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 41: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 38) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up 0 0 A and down a few times.

  • Page 42: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. ( p. 10) – Remove the seat. ( p. 64) – Take off the side cover. ( p. 65) – Remove the shock absorber. ( p.

  • Page 43: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM – Remove screw – Repeat the operation on the opposite side. 300564-10 – Loosen screw – Remove screw – Remove screw 300565-10 – Swing the rear end upwards. – Lift shock absorber upwards and remove. 300566-10 9.10 Installing the shock absorber Main work –...
  • Page 44 SHOCK ABSORBER, SWINGARM – Mount screw but do not tighten yet. – Mount and tighten screw Guideline Screw, bottom shock 45 Nm Loctite ® 243™ absorber (33.2 lbf ft) – Tighten screw Guideline Screw, top shock absorber 45 Nm Loctite ®...

  • Page 45: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM 9.11 Servicing the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Condition The shock absorber has been removed. –...

  • Page 46: Dismantling The Damper

    SHOCK ABSORBER, SWINGARM 9.13 Dismantling the damper Preparatory work – Remove the spring. ( p. 43) Main work – Establish and note the current state of the rebound damping and compression damping. – Completely open the adjusters of the rebound and compression damping. –...

  • Page 47: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM – Remove compression adjuster . Remove the spring, sleeve, and piston. 201279-10 9.14 Disassembling the piston rod Preparatory work – Remove the spring. ( p. 43) – Dismantle the damper. ( p. 44) Main work – Clamp the piston rod with the heim joint in a vise. –...

  • Page 48: Checking The Damper

    SHOCK ABSORBER, SWINGARM – Remove seal ring retainer 300542-10 – Remove locking cap and rubber buffer 300543-10 9.15 Checking the damper Condition The damper has been disassembled. – Measure the inside diameter at both ends and in the center of the damper car- tridge.

  • Page 49: Removing The Heim Joint

    SHOCK ABSORBER, SWINGARM – Check the heim joint for damage and wear. » If there is damage or wear: – Change the heim joint. 300460-01 9.16 Removing the heim joint Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. –...

  • Page 50: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM – Place special tool underneath and press out the heim joint with special tool Pressing tool (T1207S) ( p. 225) 200580-10 9.17 Installing the heim joint – Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool (T1206) ( p.

  • Page 51: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 9.18 Assembling the piston rod Preparatory work – Check the damper. ( p. 46) Main work – Clamp the piston rod with the heim joint in a vise. Guideline Use soft jaws. – Mount rubber buffer and locking cap 300543-11 –...

  • Page 52: Assembling The Damper

    SHOCK ABSORBER, SWINGARM – Mount and tighten nut Guideline Piston rod nut M12x1 40 Nm (29.5 lbf ft) 300540-11 9.19 Assembling the damper Preparatory work – Check the damper. ( p. 46) – Assemble the piston rod. ( p. 49) Main work –...
  • Page 53 SHOCK ABSORBER, SWINGARM – Grease O-ring of the seal ring retainer. Lubricant (T158) ( p. 214) – Mount the piston rod carefully. 201278-11 – Install the seal ring bearer and push it under the ring groove. – Mount lock ring Info Do not scratch the inner surface.

  • Page 54: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM 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 suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
  • Page 55 SHOCK ABSORBER, SWINGARM – Measure distance between the floating piston and reservoir hole with the special tool. Depth micrometer (T107S) ( p. 224) The floating piston is positioned all the way at the bottom. 201285-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser- voir control lever to Equalize pressure.

  • Page 56: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control lever to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge rises to the specified value. 3 bar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever to Vacuum.

  • Page 57: Installing The Spring

    SHOCK ABSORBER, SWINGARM – Clamp special tool in the vise. Nitrogen filling tool (T170S1) ( p. 227) – Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen – Adjust pressure regulator. Guideline Gas pressure 10 bar (145 psi) 201281-10 –...
  • Page 58 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.

  • Page 59: Exhaust

    EXHAUST 10.1 Removing the manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the seat. ( p. 64) –...

  • Page 60: Installing The Manifold

    EXHAUST 10.2 Installing the manifold Main work – Position the manifold with the seals. 300209-11 – Position the spacer. – Mount and tighten nuts Guideline Nut, manifold on cylinder 20 Nm Copper paste head (14.8 lbf ft) 300208-11 – Position the screw clamp. –...

  • Page 61: Removing The Main Silencer

    EXHAUST 10.3 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws – Take off the exhaust heat shield. 302044-10 –...

  • Page 62: Position The Screw Clamp

    EXHAUST – Position the screw clamp. – Tighten screw Guideline Screw, main silencer 12 Nm Copper paste clamp (8.9 lbf ft) 302045-10 – Position the exhaust heat shield. – Mount and tighten screws Guideline Loctite 243™ Screw, exhaust heat shield 8 Nm ®...

  • Page 63: Air Filter

    AIR FILTER 11.1 Removing the air filter Preparatory work – Remove the seat. ( p. 64) Main work – Remove screws . Take off air filter box top 100285-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 64: Installing The Air Filter Box

    AIR FILTER Main work – Remove screws – Take off the voltage regulator and hang it to the side in a de-energized state. – Detach and expose hose 300202-10 – Remove screws 300203-10 – Remove screws 300204-10 – Loosen hose clip 300205-10 –...

  • Page 65: Mount The Side Cover

    AIR FILTER – Position the air filter box. – Mount and tighten hose clip 300205-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300204-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300203-11 –...

  • Page 66: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 12.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 67: Mounting The Seat

    FUEL TANK, SEAT, TRIM 12.4 Mounting the seat – 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.

  • Page 68: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM – Press on the metal plate and disconnect the fuel hose connection Info Remaining fuel may run out of the fuel hose. 302037-10 – Mount special tool 0 0 3 Pressure testing tool (61029094000) ( p. 218) –...
  • Page 69 FUEL TANK, SEAT, TRIM 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. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 70 FUEL TANK, SEAT, TRIM – Disconnect both fuel hose connections – Unplug connector . Remove the fuel pump. 202048-10 – Remove hose clamps – Remove fuel filter. – Mount the new fuel filter. Arrow points away from the fuel pump. –...

  • Page 71: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM – Position the splash protector. Mount and tighten screws Guideline Remaining screws, chassis 4 Nm (3 lbf ft) 202046-10 – Position the rear end. – Mount and tighten screw on both sides. Guideline Loctite 243™ Screw, fuel tank, bottom 25 Nm ®...
  • Page 72 FUEL TANK, SEAT, TRIM 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. Preparatory work – Switch off all power consumers and switch off the engine. –...
  • Page 73 FUEL TANK, SEAT, TRIM – Disconnect both fuel hose connections – Unplug connector . Remove the fuel pump. – Connect the new fuel pump, attaching both fuel hose connections – Attach connector 202048-10 – Position the fuel pump. – Mount and tighten screws Guideline Screw, fuel pump 4 Nm (3 lbf ft)
  • Page 74 FUEL TANK, SEAT, TRIM – Set the clock. ( p. 100)

  • Page 75: Wheels

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 76: Checking The Brake Discs

    DOT marking. 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 5 years. »...

  • Page 77: Checking The Rim Run-Out

    WHEELS 13.5 Checking the rim run-out Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload.

  • Page 78: Installing The Front Wheel

    WHEELS – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.

  • Page 79: Installing The Brake Disc Of The Front Brake

    WHEELS Main work – Remove screws . Take off the brake disc. 202087-10 13.6.4 Installing the brake disc of the front brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front brake disc 14 Nm...

  • Page 80: Removing The Brake Disc Of The Rear Brake

    WHEELS Warning 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. Main work – Check the rear hub rubber dampers. ( p. 82) –...

  • Page 81: Installing The Brake Disc Of The Rear Brake

    WHEELS 13.7.4 Installing the brake disc of the rear brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, rear brake disc 14 Nm Loctite ®...

  • Page 82: Adjusting Chain Guide

    WHEELS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks...
  • Page 83 WHEELS – Pull on the upper section of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg (33 lb.) 0 0 A – Measure distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 84: Cleaning The Chain

    WHEELS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 – Check that the chain guide is firmly seated. »...
  • Page 85 WHEELS Main work – Check bearing » If the bearing is damaged or worn: – Replace the bearings. – Check rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: –...

  • Page 86: Wiring Harness, Battery

    WIRING HARNESS, BATTERY 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 87: Connecting The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 88: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the bat- tery.

  • Page 89: Changing The Main Fuse

    WIRING HARNESS, BATTERY 14.7 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery. Preparatory work –...

  • Page 90: Adjusting The Engine Characteristic

    WIRING HARNESS, BATTERY – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument Fuse 2 - 10 A - clock, ignition (EFI control unit) Fuse 3 - 10 A - EPT control unit Fuse 4 - 10 A - fuel pump Fuse 5 - 10 A - radiator fan Fuse 6 - 10 A - horn, brake light, turn signal Fuse 7 - 15 A - high beam, low beam, parking light, tail light, license plate lamp...
  • Page 91 WIRING HARNESS, BATTERY – 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. –...

  • Page 92: Brake System

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake 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.
  • Page 93 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake pistons.

  • Page 94: Checking The Free Travel Of The Hand Brake Lever

    BRAKE SYSTEM 15.3 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.

  • Page 95: Adding Front Brake Fluid

    BRAKE SYSTEM 15.6 Adding front brake fluid Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.

  • Page 96: Checking The Rear Brake Linings

    BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 97: Changing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake 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.

  • Page 98: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 400419-11 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 99: Checking Rear Brake Fluid Level

    BRAKE SYSTEM – Loosen fitting on foot brake cylinder – To adjust the basic position of the foot brake lever individually, loosen nut turn screw accordingly. Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns.

  • Page 100: Changing The Rear Brake Fluid

    BRAKE SYSTEM 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 and brake lines are not designed for DOT 5 brake fluid.
  • Page 101 BRAKE SYSTEM – Pull off protection cap and connect a commercially available suction device (standard workshop equipment). – Release bleeder screw and draw out the old brake fluid. Info During suction, ensure that the brake fluid reservoir is always filled with a sufficient amount of fresh brake fluid.

  • Page 102: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 16.1 Combination instrument 16.1.1 Setting kilometers or miles Info If you change the unit, the value is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to position ON –...

  • Page 103: Setting The Wheel Circumference

    LIGHTING SYSTEM, INSTRUMENTS – Switch on the ignition by turning the ignition key to position ON – Press the M button repeatedly until the Trip 2 mode is active. – Keep the S button pressed. The Trip 2 display is set to 0.00. 800083-20 16.1.5 Setting the wheel circumference...

  • Page 104: Checking The Headlight Setting

    LIGHTING SYSTEM, INSTRUMENTS 16.2 Checking the headlight setting – Stand the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark.

  • Page 105: Installing The Headlight Mask With The Headlight

    LIGHTING SYSTEM, INSTRUMENTS – Disconnect the electrical plug-in connection and remove the headlight mask with the headlight. 800102-10 16.5 Installing the headlight mask with the headlight Main work – Connect the electrical plug-in connection 800102-11 – Position the headlight mask and fix it with rubber band Info Make sure that the holding lugs engage in the fender.

  • Page 106: Changing The Headlight Bulb

    LIGHTING SYSTEM, INSTRUMENTS Main work – Pull bulb socket out of the reflector. – Pull parking light bulb out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1x9.5d) ( p.
  • Page 107 LIGHTING SYSTEM, INSTRUMENTS Main work (690 Enduro R EU/AUS/UK) – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off. – Lightly squeeze the orange plug in the area of the holding lugs and take it off.

  • Page 108: Engine

    ENGINE 17.1 Removing the engine Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 64) – Disconnect the battery. ( p. 84) – Raise the motorcycle with the work stand. ( p.
  • Page 109 ENGINE – Take off the engine sprocket. – Take off the clutch slave cylinder and hang it to the side. Info Do not bend the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed.

  • Page 110: Installing The Engine

    ENGINE – Remove screws . Remove the engine bearer. 300221-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 222) 300222-10 – Remove nut of the lower engine bracket. Remove the screw. 300223-10 –...
  • Page 111 ENGINE Main work – Position the engine in the frame. – Mount swingarm pivot – Mount the screw of the swingarm pivot but do not tighten yet. 300225-11 – Install the screw and nut of the lower engine bracket, but do not tighten them yet.
  • Page 112 ENGINE – Attach the spark plug connector. – Plug in the connector of the engine coolant temperature sensor 300219-11 – Reconnect plug-in connections of the gear position sensor, the crankshaft posi- tion sensor and the alternator. 300218-11 – Position the throttle valve body. –...
  • Page 113 Install and tighten the oil filler plug with O-ring 300802-10 Finishing work – Fill/bleed the cooling system. ( p. 167) – Remove the motorcycle from the work stand. ( p. 11) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool.

  • Page 114: Engine Disassembly

    ENGINE – Check the engine for leakage. – Check the engine oil level. ( p. 170) – Check the coolant level. ( p. 169) 17.3 Engine disassembly 17.3.1 Clamping the engine into the engine assembly stand – Mount special tool on engine work stand Engine assembly stand (61229001000) ( p.

  • Page 115: Removing Valve Cover

    ENGINE 17.3.4 Removing valve cover – Remove screws . Take off the valve cover with the valve cover seal. 300003-10 17.3.5 Removing the alternator cover – Remove screws . Take off the alternator cover. – Remove dowels. 300004-10 17.3.6 Removing spacer –...

  • Page 116: Removing Oil Filter

    ENGINE 17.3.8 Removing oil filter – 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. 216) 300009-10 – Remove screws. Remove the oil filter cover with the O-ring.

  • Page 117: Removing Water Pump Wheel

    ENGINE 17.3.11 Removing water pump wheel – Remove screws . Take off the water pump cover. 300012-10 – Remove screw . Take off the water pump wheel – Take off the water pump cover seal. Info Do not lose the centering pins. 300013-10 –...

  • Page 118: Removing Spark Plug

    ENGINE 17.3.14 Removing spark plug – Remove the spark plug using the special tool Spark plug wrench (75029172000) ( p. 223) 300016-10 17.3.15 Removing timing chain tensioner – Remove screw . Take off the seal ring. – Pull out timing chain tensioner 300017-10 17.3.16 Removing camshafts –...

  • Page 119: Removing Piston

    ENGINE 17.3.18 Removing piston – 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 pin. Ensure that the two grooved pins remain in place. 300030-10 –...

  • Page 120: Removing Timing Chain Rails

    ENGINE 17.3.20 Removing timing chain rails – Remove screws – Pull the timing chain guide rails out of the timing chain securing guide Info The support bushing is plugged through the timing chain guide rails into the timing chain securing guide. –...

  • Page 121: Removing Clutch Cage

    ENGINE 17.3.23 Removing clutch cage – Clamp the antihopping clutch with special tool Assembly screws (75029033000) ( p. 220) Info Apply the special tool with the hand only, do not use another tool. 300051-10 – Loosen the screws diagonally and remove them with their spring retainers and clutch springs.

  • Page 122: Removing Primary Gear

    ENGINE 17.3.24 Removing primary gear – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p. 223) – Screw the special tool on to the primary gear Extractor (75029021000) ( p. 220) – Hold it using the special tool and pull off the primary gear by turning the screw in. –...

  • Page 123: Removing Locking Lever

    ENGINE 17.3.28 Removing locking lever – Remove screw – Take off locking lever with the sleeve and spring. 300069-10 17.3.29 Removing oil pumps – Remove the lock washers and normal washers from both oil pumps. – Take off the oil pump toothed wheels 300070-10 –...

  • Page 124: Removing Crankshaft And Balancer Shaft

    ENGINE – Install the special tool with suitable screws. Extractor (75029048000) ( p. 221) Info Use the 750 drill hole. – Pull off the section of the engine case. Info 300076-10 Do not tension the section of the engine case. The balancer shaft and the main shaft have a stop disk, these usually stick to the bearing.

  • Page 125: Work On Individual Parts

    ENGINE – Remove shift forks Info Ensure that the pins remain in place. 300081-10 – Remove the lock ring and the stop disk. 300082-10 – Pull both transmission shafts out of the bearing seats together. Info The stop disk of the countershaft usually sticks to the bearing. –...
  • Page 126 ENGINE – Warm the engine case section again. Guideline 150 °C (302 °F) – 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.

  • Page 127: Work On The Left Section Of The Engine Case

    ENGINE 17.4.2 Work on the left section of the engine case – Remove all dowels. – Remove oil jet – Remove the shaft seal ring of countershaft and shift shaft Info The shaft seal ring of the crankshaft cannot be removed before the crankshaft bearing.

  • Page 128: Work On The Clutch Cover

    ENGINE – Mount and tighten screw with the washer. Guideline Locking screw for bearing 6 Nm Loctite ® 243™ (4.4 lbf ft) – Press in the shaft seal ring of countershaft and shift shaft with the open side facing inwards so that it is flush. –...

  • Page 129: Removing Crankshaft Bearing Inner Ring

    ENGINE 17.4.4 Removing crankshaft bearing inner ring – Fix the crankshaft with special tools in the vise. Upper part, pressing-out tool (75029047050) ( p. 221) Under part, pressing-out tool (75029047051) ( p. 221) 300135-10 – Heat the special tool Guideline 150 °C (302 °F) Tool for inner bearing race (58429037043) ( p.
  • Page 130 ENGINE – Press the crank pin out of the crankweb. 300138-10 – Press in the new crank pin as far as possible. Info The crank pin must be pressed in so that oil channel is aligned with oil channel If the oil channels are not correctly aligned, the conrod bearing will not be supplied with oil.

  • Page 131: Checking Crankshaft Run-Out At Bearing Pin

    ENGINE – Install the crankshaft bearing inner ring. ( p. 129) – Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 130) 17.4.7 Checking crankshaft run-out at bearing pin – Position the crankshaft on a roller block. –...

  • Page 132: Measuring Axial Clearance Of Crankshaft And Balancer Shaft

    ENGINE – Repeat the operation on the opposite side. – Make sure that the new inner bearing race is installed flush. Info After changing the crankshaft bearing and the conrod bearing, measure the axial play of the crankshaft. Finishing work –...

  • Page 133: Checking/Measuring The Cylinder

    ENGINE 17.4.12 Checking/measuring the cylinder – Check the O-ring of the chain adjuster for damage and wear. » If there is damage or wear: – Replace the O-ring. – Check the cylinder bearing surface for damage. » If the cylinder bearing surface is damaged: –...

  • Page 134: Checking Piston Ring End Gap

    ENGINE – Check the piston rings for damage. » If the piston ring is damaged: – Change the piston ring. Info Mount the piston ring with the marking facing upward. – Check the piston pin for discoloration or signs of wear. »...

  • Page 135: Checking Oil Pumps For Wear

    ENGINE 17.4.16 Checking oil pumps for wear Info The oil pump wear check shown here is on the suction pump but it applies to all oil pumps. – 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.

  • Page 136: Preparing Timing Chain Tensioner For Installation

    ENGINE – Mount the autodecompression shaft in the camshaft. Install a new lock ring. – Check the functioning. » If the autodecompression spring does not completely retract the autodecom- pression shaft: – Replace the autodecompression spring. 17.4.18 Preparing timing chain tensioner for installation –...

  • Page 137: Removing Rocker Arm

    ENGINE 17.4.20 Removing rocker arm – Remove screws 300113-10 – Screw a suitable screw into the rocker arm shafts . Pull out the rocker arm shafts. – Take off the rocker arm 300114-10 17.4.21 Changing camshaft bearing Preparatory work – Remove the rocker arm.

  • Page 138: Removing Valves

    ENGINE – Press in the large camshaft bearing as far as possible using the special tool Push-in drift (75029044010) ( p. 220) 300230-10 Finishing work – Install the rocker arm. ( p. 139) 17.4.22 Removing valves – Take shims out of the valve spring retainers and lay them to one side according to their normal built-in position.

  • Page 139: Checking Valve Springs

    ENGINE – Check the sealing seat on the valve. Valve - sealing seat width Intake 1.60 mm (0.063 in) 0 0 A Valve - sealing seat width Exhaust 2.00 mm (0.0787 in) » If the sealing area is not in the center of the valve seat or deviates from the specified value: 400373-10 –...

  • Page 140: Installing Valves

    ENGINE – Check sealing seat of the valves. Valve - sealing seat width Intake 1.60 mm (0.063 in) 0 0 A Valve - sealing seat width Exhaust 2.00 mm (0.0787 in) » If the measured value does not equal the specified value: –...

  • Page 141: Installing Rocker Arm

    ENGINE 17.4.28 Installing rocker arm – Position the rocker arm and push in the rocker arm shafts Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards. The small drill hole and the flat surface must point upwards. 300114-11 –...
  • Page 142 ENGINE 0 0 bk 0 0 4 0 0 5 0 0 6 0 0 2 0 0 9 0 0 b l 0 0 1 0 0 b o 0 0 3 0 0 b n 0 0 b m 0 0 7 0 0 8 300123-01...

  • Page 143: Preassembling The Antihopping Clutch

    ENGINE – Check clutch facing discs for discoloration and scoring. » If there is discoloration or scoring: – Change all clutch facing discs. – Check the thickness of clutch facing discs ≥ 2.5 mm (≥ 0.098 in) Clutch facing disc - thickness »...

  • Page 144: Checking Shift Mechanism

    ENGINE 17.4.32 Checking shift mechanism – Check the shift forks (see ) for damage and wear (visual check). 0 0 A » If there is damage or wear: – 0 0 1 Change the shift fork and gear wheel pair. 0 0 4 0 0 1 –...

  • Page 145: Disassembling The Main Shaft

    ENGINE 17.4.34 Disassembling the main shaft 301980-01 – Fix the main shaft 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 –...

  • Page 146: Checking The Transmission

    ENGINE – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk – Remove fifth-gear sliding gear and lock ring – Remove stop disk and third-gear idler gear – Remove needle bearing and the fourth-gear idler gear –...

  • Page 147: Assembling The Main Shaft

    ENGINE » If the sliding gear does not move easily: – Change the sliding gear or the main shaft. – Check sliding gears for smooth operation in the profile of countershaft » If the fixed gear does not move easily: –...

  • Page 148: Assembling Countershaft

    ENGINE 17.4.38 Assembling countershaft Info Use new lock rings in every repair job. Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 144) Main work 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –...

  • Page 149: Checking The Starter Drive

    ENGINE 17.4.39 Checking the starter drive 300129-01 – Check the teeth and seating of the starter idler gear for damage and wear. » If there is damage or wear: – Replace the starter idler gear and/or needle bushing. – Check the teeth and seating of the torque limiter for damage and wear.

  • Page 150: Checking Freewheel

    ENGINE – Compress the expansion ring and remove it, using suitable pliers. – Take the freewheel out of the primary gear. 300128-10 17.4.41 Checking freewheel – Insert the freewheel gear in the primary gear , turning the primary gear clock- wise;...

  • Page 151: Engine Assembly

    ENGINE – Insert the lock ring into the groove with suitable pliers and check that it is seated correctly. 300127-11 17.5 Engine assembly 17.5.1 Installing transmission shafts – Clamp the right section of the engine case. Holder for engine assembly stand (75012001070) ( p.

  • Page 152: Installing Crankshaft And Balancer Shaft

    ENGINE – Install the shift rail – Check the transmission for smooth operation. 300079-11 – Install the shim and lock ring of the countershaft. 300082-11 17.5.2 Installing crankshaft and balancer shaft – Mount the special tool on the alternator side of the crankshaft. Mounting sleeve (75029080000) ( p.

  • Page 153: Installing Left Engine Case

    ENGINE 17.5.3 Installing left engine case – Mount the dowels. – Mount the O-ring – Degrease the sealing area. Apply the sealing compound to the left engine case half. Loctite ® 5910 300077-11 – Put on the left engine case half. If necessary, tap lightly with a rubber mallet and turn the transmission shafts.

  • Page 154: Installing Locking Lever

    ENGINE 17.5.5 Installing locking lever – Position locking lever with sleeve and spring – Mount and tighten screw Guideline Screw, locking lever 10 Nm Loctite ® 243™ (7.4 lbf ft) 300069-11 17.5.6 Installing shift drum locating – Press locking lever down and position shift drum locating.

  • Page 155: Installing Primary Gear

    ENGINE – Push on the starter idler gear with washer. Mount lock ring. – Push on the needle bearing and torque limiter with washer. Mount lock ring. 300064-11 17.5.9 Installing primary gear – Ensure that the spring washer is seated properly. –...

  • Page 156: Installing Crankshaft Position Sensor

    ENGINE – Position a new lock washer and install the nut – Lock the clutch basket and primary gear using the special tool and tighten the nut. Guideline Nut, inner clutch hub M20x1.5 100 Nm Loctite ® 243™ (73.8 lbf ft) Gear segment (75029081000) ( p.

  • Page 157: Installing Timing Chain And Timing Chain Sprocket

    ENGINE 17.5.12 Installing timing chain and timing chain sprocket – Heat the timing chain sprocket and push it immediately on to the crankshaft. Guideline 100 °C (212 °F) – Mount lock ring 300150-10 – Thread the timing chain in and lay it over the timing chain sprocket. Info If the timing chain is not new, pay attention to the direction of travel.

  • Page 158: Adjusting Crankshaft Position Sensor Distance

    ENGINE – Mount the tab washer and the nut . Tighten nut. Guideline Rotor nut M18x1.5 100 Nm (73.8 lbf ft) 300043-10 17.5.15 Adjusting crankshaft position sensor distance – Adjust the distance between the crankshaft position sensor and the conductive element of the rotor using the special tool Guideline Crankshaft position sensor/rotor -...
  • Page 159 ENGINE – Ensure that piston marking faces the outfeed side. 300035-10 – Apply a thin layer of sealing compound in area Loctite ® 5910 – Place the cylinder base gasket on. Info Make sure the grooved pins are seated correctly. 300034-10 –...

  • Page 160: Installing Cylinder Head

    ENGINE – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the grooved pins engage. 300039-10 17.5.18 Installing cylinder head – Put on the cylinder head gasket. Info Make sure the grooved pins are seated correctly. –...

  • Page 161: Installing Timing Chain Tensioner

    ENGINE – Position the camshaft support plate . Mount and tighten screw Guideline Screw, camshaft support 10 Nm Loctite ® 243™ plate (7.4 lbf ft) 300022-10 17.5.20 Installing timing chain tensioner – Insert the timing chain tensioner – Mount and tighten plug with the new seal ring.

  • Page 162: Adjusting Valve Clearance

    ENGINE – Remove the special tool. Engine blocking screw (77329010000) ( p. 223) – Mount and tighten screw with the washer. Guideline Screw plug, crankshaft clamp 20 Nm (14.8 lbf ft) 306140-10 17.5.22 Adjusting valve clearance – Remove screws Info Make sure that the crankshaft is at top dead center.

  • Page 163: Installing Spark Plug

    ENGINE 17.5.23 Installing spark plug – 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. 223) 300016-11 17.5.24 Installing spacer and spring – Install the spacer and spring of the shift shaft.

  • Page 164: Installing Thermostat

    ENGINE – Put on the water pump cover . Mount and tighten screws. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 300012-12 17.5.27 Installing thermostat – Position the thermostat with the gasket. The drill hole must face upward. –...

  • Page 165: Installing The Spacer

    ENGINE – Install the gear position sensor – Position the ground wire – Mount and tighten the screws. Guideline Loctite ® 243™ Screw, gear sensor 5 Nm (3.7 lbf ft) 302126-11 17.5.30 Installing the spacer – Grease spacer in area and O-ring before mounting.

  • Page 166: Installing Alternator Cover

    ENGINE – Position the oil screen with O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 300161-11 17.5.32 Installing alternator cover – Apply sealing compound lightly in the area of the cable sleeve. –...

  • Page 167: Installing Valve Cover

    ENGINE 17.5.34 Installing valve cover – Put the valve cover in place with the seal. Mount and tighten screws Guideline Screw, valve cover 10 Nm (7.4 lbf ft) 300003-10 17.5.35 Removing the engine from the engine assembly stand – Remove the screw or the nut –...

  • Page 168: Clutch

    CLUTCH 18.1 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 169: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM 19.1 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 170: Checking The Antifreeze And Coolant Level

    WATER PUMP, COOLING SYSTEM – Remove the cap from compensating tank and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

  • Page 171: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p. 212) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 172: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 400500-60 Oil circuit of force pump Oil screen Force pump Oil filter Oil pressure regulator valve Timing chain tensioner Rocker arm shaft Transmission Clutch Oil jet for piston cooling Oil filter Oil nozzle for conrod bearing lubrication Oil circuit of suction pump Oil screen Suction pump...

  • Page 173: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer. » If the engine oil level is not at the specified level: –...

  • Page 174: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM – Change the oil filter. Check oil pumps for wear. Check all oil channels for free flow. – Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

  • Page 175: Removing The Oil Filter

    LUBRICATION SYSTEM – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 100201-01 20.6 Removing the oil filter Warning...

  • Page 176: Cleaning The Oil Screens

    LUBRICATION SYSTEM 20.8 Cleaning the oil screens 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 substances cause environmental damage.

  • Page 177: Filling Up With Engine Oil

    LUBRICATION SYSTEM 20.9 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)

  • Page 178: Ignition System

    IGNITION SYSTEM 21.1 Alternator - checking the stator winding Condition The stator is disconnected. Preparatory work – Remove the seat. ( p. 64) – Take off the side cover. ( p. 65) Main work Stator winding, measurement I - check the resistance –...

  • Page 179: Ignition Coil - Checking The Secondary Winding

    IGNITION SYSTEM 21.3 Ignition coil - checking the secondary winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Preparatory work – Remove the seat. ( p. 64) – Remove the fuel tank. Main work Ignition coil cylinder 1 - check the secondary winding resistance –...

  • Page 180: Technical Data

    TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11.8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)
  • Page 181 TECHNICAL DATA Exhaust 2.00 mm (0.0787 in) Valve - run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate ≤ 0.05 mm (≤ 0.002 in) On the valve stem ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion Cylinder - bore diameter Size I 102.000…...

  • Page 182: Engine Tightening Torques

    TECHNICAL DATA 22.3 Engine tightening torques ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) ® Oil nozzle for conrod bearing lubrica- 2 Nm (1.5 lbf ft) Loctite 243™...

  • Page 183: Capacities

    TECHNICAL DATA ® Screw plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Screw plug, oil channel, for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner –...

  • Page 184: Electrical System

    12 V 35/35 W Parking light W5W / socket W2.1x9.5d 12 V Instrument lights and indicator lamps Turn signal (690 Enduro R EU/AUS/UK) R10W / socket BA15s 12 V 10 W Turn signal (690 Enduro R USA) RY10W / socket BAU15s...

  • Page 185: Fork

    TECHNICAL DATA 22.8 Fork Fork part number 14.18.7K.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 Spring length with preload spacer(s) 495 mm (19.49 in)

  • Page 186: Chassis Tightening Torques

    TECHNICAL DATA Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 213) 22.10 Chassis tightening torques – Screw, chain guard EJOT 2 Nm (1.5 lbf ft) – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) –...
  • Page 187 TECHNICAL DATA ® Screw, foot brake lever 25 Nm (18.4 lbf ft) Loctite 243™ – Screw, fork stub 15 Nm (11.1 lbf ft) ® Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite 243™ – Screw, front footrest bracket 25 Nm (18.4 lbf ft) –...

  • Page 188: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 23.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 189: Checks And Maintenance Steps For Winter Operation

    CLEANING/PROTECTIVE TREATMENT 23.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres- sive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 190: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 10) – Cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 191: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● Make the service entry in KTM DEALER.NET and in the service record.
  • Page 192 SERVICE SCHEDULE ○ One-time interval ● Periodic interval...

  • Page 194: Wiring Diagram

    WIRING DIAGRAM 26.1 Page 01 of 10 wh-rd rd-bu wh-rd wh-rd wh-rd EM/3 EN/3 bl-rd rd-bu bl-rd ye-rd wh-rd ye-rd 401227-01...
  • Page 195 WIRING DIAGRAM Components: EFI control unit Fuse Battery Alternator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator Connector for accessory ground (terminal 31) ACC 1 (not assigned) X291 X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)

  • Page 196: 194

    WIRING DIAGRAM 26.2 Page 02 of 10 ye-rd bl-rd ye-rd ye-rd ye-rd wh-rd wh-rd wh-rd wh-rd wh-rd ye-rd wh-bl wh-bl ye-rd wh-rd ye-rd ye-rd 401228-01...
  • Page 197 WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Light relay Power relay Combination instrument Ignition/steering lock Emergency OFF switch, electric starter button X295 Diagnostics connector...

  • Page 198: 196

    WIRING DIAGRAM 26.3 Page 03 of 10 ye-bu Mode Down ye-bu 401229-01...
  • Page 199 WIRING DIAGRAM Components: Low beam, high beam Fuse Fuse Combination instrument Horn Parking light High beam/low beam switch, horn button, turn signal switch Tripmaster switch (optional)

  • Page 200: 198

    WIRING DIAGRAM 26.4 Page 04 of 10 wh-gn ye-bu wh-gn ye-bu wh-gn 401230-01...
  • Page 201 WIRING DIAGRAM Components: Front brake light switch Brake light switch, rear License plate lamp Brake/tail light...

  • Page 202: 200

    WIRING DIAGRAM 26.5 Page 05 of 10 bl-or ye-bu bl-or 401231-01...
  • Page 203 WIRING DIAGRAM Components: Turn signal relay Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right High beam/low beam switch, horn button, turn signal switch...

  • Page 204: 202

    WIRING DIAGRAM 26.6 Page 06 of 10 bl-rd bl-rd wh-bl wh-bl 401232-01...
  • Page 205 WIRING DIAGRAM Components: Temperature switch for radiator fan Fuse Fuse 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 206: 204

    WIRING DIAGRAM 26.7 Page 07 of 10 br-pu br-pu br-pu br-pu ye-rd br-pu bl-bu bu-gr bu-gr bl-rd wh-br gn-or wh-bu bl-bu bl-bu ye-rd bu-or ye-rd bl-bu wh-bu gn-or wh-br bl-rd bl-rd br-pu bu-or bu-br bu-br wh-gn wh-gn wh-rd wh-rd wh-or wh-or 401233-01...
  • Page 207 WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Fuse Fuse Fuel pump Motor drive Combination instrument X295 Diagnostics connector...

  • Page 208: 206

    WIRING DIAGRAM 26.8 Page 08 of 10 bl-or bl-or rd-gr rd-gr bl-gr bl-gr wh-pu wh-pu gn-rd gn-rd 401234-01...
  • Page 209 WIRING DIAGRAM Components: EFI control unit Lambda sensor (cylinder 1) Front wheel speed sensor Fuel evaporation valve (USA version only) Secondary air valve Injector (cylinder 1) Combination instrument Ignition coil (cylinder 1)

  • Page 210: 208

    WIRING DIAGRAM 26.9 Page 09 of 10 ye-gn ye-gn wh-pk wh-pk ye-or ye-or ye-br ye-br bl-gn bl-gn bl-gn 401235-01...
  • Page 211 WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Rollover sensor Side stand switch Accelerator position sensor Gear position sensor Combination instrument...

  • Page 212: 210

    WIRING DIAGRAM 26.10 Page 10 of 10 gn-gr gn-gr wh-ye wh-ye ye-bu ye-bu bl-br bl-br bl-ye bl-ye bu-or bu-or br-rd br-rd 401236-01...
  • Page 213 WIRING DIAGRAM Components: EFI control unit Ambient air pressure sensor Engine coolant temperature sensor (cylinder 1) Fuel level indicator Crankshaft position sensor Clutch switch Manifold absolute pressure sensor (cylinder 1) Combination instrument Map‑Select Switch Cable colors: Black Brown Blue Green Gray Light blue Orange...

  • Page 214: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 215 Hydraulic fluid (15) According to – ISO VG (15) Guideline – 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 ® –...

  • Page 216: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Protect & Shine...
  • Page 217 AUXILIARY SUBSTANCES Lubricant (T625) Guideline – KTM recommends Molykote ® products. Supplier Molykote ® – 33 Medium Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Off-road chain spray Guideline – KTM recommends Motorex ®...

  • Page 218: Special Tools

    SPECIAL TOOLS Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400125-01 Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58429009000 400073-01...
  • Page 219 SPECIAL TOOLS Tool for inner bearing race Art. no.: 58429037043 400082-01 Mounting sleeve Art. no.: 58529005000 400095-01 Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01...
  • Page 220 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 400110-01 Hose clamp pliers Art. no.: 60029057000 400142-01 Pliers for spring band clamp Art. no.: 60029057100 400085-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01...
  • Page 221 SPECIAL TOOLS Engine assembly stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01 Support for engine assembly stand Art. no.: 75012001060 400153-01 Holder for engine assembly stand Art. no.: 75012001070 400154-01 Piston assembly ring Art. no.: 75029015102 400156-01...
  • Page 222 SPECIAL TOOLS Extractor Art. no.: 75029021000 400157-01 Assembly screws Art. no.: 75029033000 400158-01 Insertion for piston ring lock Art. no.: 75029035000 400160-01 Work stand adapter Art. no.: 75029036000 400161-01 Push-in drift Art. no.: 75029044010 500163-01...
  • Page 223 SPECIAL TOOLS Push-in drift Art. no.: 75029044020 500162-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01 Upper part, pressing-out tool Art. no.: 75029047050 400186-01 Under part, pressing-out tool Art. no.: 75029047051 400187-01 Extractor Art. no.: 75029048000 400162-01...
  • Page 224 SPECIAL TOOLS Clamping plate Art. no.: 75029050000 400163-01 Push-out drift Art. no.: 75029051000 400164-01 Floor jack attachment Art. no.: 75029055000 400184-01 Mounting sleeve Art. no.: 75029080000 400165-01 Gear segment Art. no.: 75029081000 400068-01...
  • Page 225 SPECIAL TOOLS Protection cover Art. no.: 75029090000 400167-01 Holding spanner Art. no.: 75029091000 400168-01 Spark plug wrench Art. no.: 75029172000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01 Engine blocking screw Art. no.: 77329010000 400177-01...
  • Page 226 SPECIAL TOOLS Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Valve spring mounting device Art. no.: 78029060000 500165-01 Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10...
  • Page 227 SPECIAL TOOLS Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Vacuum pump Art. no.: T1240S 200273-10 Pressing tool Art. no.: T129 200584-01 Protecting sleeve Art. no.: T1401 200635-10...
  • Page 228 SPECIAL TOOLS Clamping stand Art. no.: T14015S 200733-10 Clamping stand Art. no.: T14016S 200688-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10 Open-end wrench Art. no.: T14032 200640-10...
  • Page 229 SPECIAL TOOLS Clamping stand Art. no.: T1403S 200637-10 Mounting sleeve Art. no.: T1515 300569-10 Nitrogen filling tool Art. no.: T170S1 300574-10...

  • Page 230: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 231: Index

    INDEX front brake, removing ......76 INDEX rear brake, installing ......79 Accessories .
  • Page 232 INDEX freewheel, removing ......147 left engine case section ..... . 125 Disassembling the engine main shaft, assembling .
  • Page 233 INDEX fitting ........16 Oil filter fork, servicing .
  • Page 234 INDEX Side cover mounting ....... . 65 removing ....... . . 65 Spare parts .
  • Page 235 *3206121en* 3206121en 10/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

690 enduro raus/uk690 enduro r usa

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