Page 1 REPAIR MANUAL 2008 690 Enduro EU 690 Enduro AUS/UK 690 Enduro USA Article no. 3206041en...
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
CONTENTS Removing the heim joint ..........42 CONTENTS MEANS OF REPRESENTATION ..........5 Installing the heim joint ..........43 IMPORTANT NOTES ............6 Assembling the piston rod ..........44 LOCATION OF SERIAL NUMBERS ........7 Assembling the damper..........45 Chassis number/type label (690 Enduro EU, 690 Enduro AUS/UK) ............
Page 5 CONTENTS Checking the rear brake linings ........81 Removing balancer shaft drive wheel ......114 Changing rear brake linings ..........82 Changing the conrod bearing ........114 Checking the free travel of foot brake lever....... 83 Checking crankshaft run-out at bearing pin ....116 Adjusting the basic position of the foot brake lever ...
Page 6 CONTENTS Installing spark plug ............ 148 SERVICE SCHEDULE............187 Installing spacer and spring.......... 148 Service schedule ............187 Installing clutch cover..........148 WIRING DIAGRAM ............188 Mounting water pump cover.......... 149 Page 1 of 10............... 188 Installing thermostat............ 149 Page 2 of 10............... 190 Installing the oil filter ..........
Page 7: Means Of Representation
MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following. 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). Identifies a page reference (more information is provided on the specified page). Indicates information with more details or tips.
Page 8: Important Notes
Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; otherwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
Page 9: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number/type label (690 Enduro EU, 690 Enduro AUS/UK) The chassis number is stamped on the right of the steering head.  The type label is on the right of the frame behind the steering head. ...
Page 10: Fork Part Number
LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  800072-10 Shock absorber part number The shock absorber part number is on the right of the shock absorber. ...
Page 11: 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 12: 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 13: Starting The Motorcycle To Make Checks
MOTORCYCLE Info Do not press the electric starter button until the function test of the combi- nation instrument 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 14: 01/Fork, Triple Clamp
01/FORK, TRIPLE CLAMP Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection covers  – 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 15: Cleaning The Dust Boots Of The Fork Legs
01/FORK, TRIPLE CLAMP – Remove bleeder screws briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs. 100248-10 Cleaning the dust boots of the fork legs –...
Page 16: Removing Fork Legs
01/FORK, TRIPLE CLAMP Removing fork legs – Raise the motorcycle with the lift stand. ( p. 9) – Tie the rear of the vehicle down. – Remove screws  – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.
Page 17: Installing The Fork Legs
01/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 18: Servicing The Fork
01/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 19: Disassembling The Fork Legs
01/FORK, TRIPLE CLAMP Disassembling the fork legs 5.10 Info These operations are the same on both fork legs. Condition The fork legs have been removed. – Remove protection cap  – Note down the current state of the rebound and compression damping ...
Page 20 01/FORK, TRIPLE CLAMP – Clamp the special tool in the vise. Loosen the screw cover  200647-12 – Remove screw cover with preload spacers   – Remove the adjusting tube  200648-12 – Pull the spring downward. Remove the special tool. –...
Page 21: Disassembling The Cartridge
01/FORK, TRIPLE CLAMP – Remove dust boot  200735-10 – Remove lock ring  Info The lock ring has a beveled end where a screwdriver can be applied. 200656-01 – Heat up the outer tube in area of the lower sliding bushings. ...
Page 22 01/FORK, TRIPLE CLAMP – Clamp the special tool in a vise. Pin (T605) ( p. 223) – Attach cartridge using the drilled holes.  200693-10 – Loosen and remove screw sleeve  200694-10 – Pull piston rod out of cartridge ...
Page 23: Disassembling The Tap Compression
01/FORK, TRIPLE CLAMP – Remove piston  – Completely remove shim stack  200699-10 – Remove spring  – Loosen and remove tap rebound  200700-10 – Remove spring  – Remove valve of the rebound damping with the spring. ...
Page 24: Checking The Fork Legs
01/FORK, TRIPLE CLAMP – Remove O-ring and seal ring from the tap compression.   – Unclamp the tap compression. 200704-10 Checking the fork legs 5.13 Condition Fork dismantled. – Check the inner tube and the axle clamp for damage. »...
Page 25: Assembling The Tap Compression
01/FORK, TRIPLE CLAMP – Check the surface of the sliding bushings. » If the bronze-colored layer under sliding layer is visible:   – Replace the sliding bushings. 200665-10 – Check the spring length. Guideline Spring length with preload spacer(s) 472 mm (18.58 in) »...
Page 26: Assembling The Cartridge
01/FORK, TRIPLE CLAMP Assembling the cartridge 5.15 Info These operations are the same on both fork legs. – Clamp the piston rod. Clamping stand (T14016S) ( p. 222) – Mount valve of the rebound damping with the spring and O-ring. ...
Page 27: Assembling The Fork Legs
01/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. – Slide piston rod into cartridge   200721-10 – Clamp the special tool in a vise.
Page 28 01/FORK, TRIPLE CLAMP – Remove the special tool. – Sand the edges of the sliding bushes with 600-grit sandpaper, then clean and grease them. Fork oil (SAE 5) ( p. 209) 200670-10 – Push on the lower sliding bushing  –...
Page 29 01/FORK, TRIPLE CLAMP – Mount adjusting tube of the rebound damping in the cartridge.  The adjusting tube protrudes 5 mm from the cartridge and can be pressed in against the resistance of the spring. The adjusting tube protrudes more than 7 mm from the cartridge and cannot be pressed in against the resistance of the spring.
Page 30 01/FORK, TRIPLE CLAMP – Clamp the special tool in the vise. – Grease the thread of the piston rod. Lubricant (T159) ( p. 210) – Lubricate top edge of the piston rod.  Lubricant (T158) ( p. 210) – Screw the screw cover with the preload spacers on to the piston rod. Info 200680-10 The screw cover must be screwed to the stop before the piston rod starts...
Page 31: Checking The Steering Head Bearing Play
01/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 spring elements can cause a serious deterioration in the handling characteristics and overload some components.
Page 32: 02/Handlebar, Instruments
02/HANDLEBAR, INSTRUMENTS 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. ...
Page 33: Adjusting The Play In The Throttle Cable
31) Adjusting the play in the throttle cable – 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 34: 03/Frame
03/FRAME Removing the engine guard – Stand the motorcycle on its side stand on a horizontal surface. – Remove screws on the left and right.  – Pull the engine guard forward out of the holders and set it down. 100198-10 Installing the engine guard –...
Page 35: 04/Shock Absorber, Swingarm
04/SHOCK ABSORBER, SWINGARM Adjusting high-speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting can be seen during the fast compression of the shock absorber. –...
Page 36: Adjusting Rebound Damping Of The Shock Absorber
04/SHOCK ABSORBER, SWINGARM Adjusting rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. – Turn adjusting screw clockwise up to the last perceptible click.
Page 37: Checking The Riding Sag Of The Shock Absorber
04/SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 34)  – 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 38: Adjusting The Riding Sag
04/SHOCK ABSORBER, SWINGARM Adjusting the riding sag – Remove the shock absorber. ( p. 36) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Soft 75 N/mm (428 lb/in) Medium (standard) 80 N/mm (457 lb/in) Hard 85 N/mm (485 lb/in)
Page 39: Installing The Shock Absorber
04/SHOCK ABSORBER, SWINGARM – Loosen screw  – Remove screw  – Remove screw  300565-10 – Swing the rear end upwards. – Lift shock absorber upwards and remove.  300566-10 Installing the shock absorber 8.10 – Swing the rear end upwards and insert shock absorber from above.
Page 40: Servicing The Shock Absorber
04/SHOCK ABSORBER, SWINGARM – Mount and tighten screw  Guideline Screw, fuel tank, bottom 20 Nm (14.8 lbf ft) – Repeat the operation on the opposite side. 300564-11 – Lift the rear fairing. – Mount and tighten screws  Guideline Screw, main silencer 25 Nm Loctite...
Page 41: Removing The Spring
04/SHOCK ABSORBER, SWINGARM Removing the spring 8.12 Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. – Measure and note spring length in preloaded state. – Loosen retaining ring and the adjusting ring with the special tool.
Page 42: Disassembling The Piston Rod
04/SHOCK ABSORBER, SWINGARM – Press in seal ring retainer . Remove lock ring   Info Do not scratch the inner surface. 300585-10 – Remove screw . Drain the oil.  300586-10 – Remove the piston rod. Drain the remaining oil. 300587-10 –...
Page 43: Checking The Damper
04/SHOCK ABSORBER, SWINGARM – Remove supporting plate and rebound shim stack together with piston    Info Thread the rebound shim set on a screwdriver and set the parts down together. 300541-10 – Remove compression shim stack with supporting plate ...
Page 44: Removing The Heim Joint
04/SHOCK ABSORBER, SWINGARM – Measure the diameter of the piston rod. Piston rod ≥ 17.95 mm (≥ 0.7067 in) Diameter » If the specification is not reached: – Change the piston rod. – Measure the run-out of the piston rod. Piston rod 300554-10 ≤...
Page 45: Installing The Heim Joint
04/SHOCK ABSORBER, SWINGARM – Remove lock rings on both sides.  200579-10 – Place special tool underneath and press out the heim joint with special tool   Pressing tool (T1207S) ( p. 221) 200580-10 Installing the heim joint 8.17 –...
Page 46: Assembling The Piston Rod
04/SHOCK ABSORBER, SWINGARM Assembling the piston rod 8.18 – Check the damper. ( p. 41) – Clamp the piston rod with the heim joint in a vise. – Mount rubber buffer and locking cap   300543-11 – Position special tool on the piston rod.
Page 47: Assembling The Damper
04/SHOCK ABSORBER, SWINGARM Assembling the damper 8.19 – Assemble the piston rod. ( p. 44) – Position membrane  – Mount and tighten membrane cover  – Mount lock ring  300590-10 – Push the spring and sleeve onto the compression damping adjuster. Attach the pis- ton.
Page 48 04/SHOCK ABSORBER, SWINGARM – Mount locking cap of the damper cartridge.  – Bleed and fill the damper. ( p. 47) – Fill the damper with nitrogen. ( p. 49) 300594-10 Alternative 1 – Turn the adjusting screw clockwise with a screwdriver up to the last percep- ...
Page 49: Bleeding And Filling The Damper
04/SHOCK ABSORBER, SWINGARM Bleeding and filling the damper 8.20 Info Before working with the vacuum pump, be sure to read the operating instructions carefully. Completely open the adjusters of the rebound and compression damping. – Remove the screw of the filling port. –...
Page 50 04/SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control  lever to Vacuum. Guideline 3 bar The pressure gauge falls to the specified value. 0 bar 200269-10 – When the pressure gauge reaches the specified value, turn the Oil reservoir con- ...
Page 51: Filling The Damper With Nitrogen
04/SHOCK ABSORBER, SWINGARM – Mount and tighten screw  Guideline Filling port screw M10x1 14 Nm (10.3 lbf ft) 300600-10 Filling the damper with nitrogen 8.21 – Clamp the damper in the vise using soft jaws. – Mount special tool on the damper connector.
Page 52 04/SHOCK ABSORBER, SWINGARM Guideline Spring rate Soft 75 N/mm (428 lb/in) Medium (standard) 80 N/mm (457 lb/in) Hard 85 N/mm (485 lb/in) – Tension the spring with the special tool. Spring compressor (T101S) ( p. 220) – Install the spring retainer ...
Page 53: 05/Exhaust
05/EXHAUST Removing the exhaust 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. – Remove the air filter box. ( p. 55) –...
Page 54: Removing The Main Silencer
05/EXHAUST – Position the spacer. – Position the manifold at the front with the seals. – Mount and tighten nuts  Guideline Nut, manifold on cylinder 25 Nm Copper paste head (18.4 lbf ft) 300208-11 – Position the exhaust clamp. –...
Page 55: Installing The Main Silencer
05/EXHAUST – Loosen screw  302045-10 – Remove screws  – Lift the rear fairing. 302046-10 – Remove screws  – Remove the main silencer. 302047-10 Installing the main silencer – Position the main silencer. – Mount and tighten screws ...
Page 56 05/EXHAUST – Mount and tighten screws  Guideline Rear fairing screw 2 Nm (1.5 lbf ft) 302046-11...
Page 57: 06/Air Filter
06/AIR FILTER Removing the air filter 10.1 – Remove the seat. ( p. 58) – Remove screws . Remove filter box top   100285-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
Page 58: Installing The Air Filter Box
06/AIR FILTER – Remove screws  300203-10 – Remove screws  300204-10 – Loosen hose clip  300205-10 – Raise the air filter box at the rear. – Loosen the spring-loaded band-type clamp with the special tool and detach bleed hose ...
Page 59 06/AIR FILTER – 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 – Position the voltage regulator. – Mount and tighten screws ...
Page 60: 07/Fuel Tank, Seat, Trim
07/FUEL TANK, SEAT, TRIM Opening filler cap 11.1 – Lift the cover of the filler cap and insert the ignition key.  – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 100227-10 Closing filler cap 11.2...
Page 61: Mounting The Side Cover
07/FUEL TANK, SEAT, TRIM Mounting the side cover 11.6 – Attach the side cover in area and engage it in area   – Mount and tighten screws  Guideline Screw, side cover 2 Nm (1.5 lbf ft) – Repeat the operation on the opposite side. –...
Page 62: Changing The Fuel Filter
07/FUEL TANK, SEAT, TRIM – Select "Fuel pump relay function test". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Guideline Maximum duration of actuator test 3 min –...
Page 63 07/FUEL TANK, SEAT, TRIM – Lift the rear fairing. – Remove screws  300563-10 – Remove screw  – Repeat the operation on the opposite side. – Swing the rear end upwards and secure it. 300564-10 – Remove screws  –...
Page 64 07/FUEL TANK, SEAT, TRIM – Mount fuel filter  Arrow points away from the fuel pump.  – Mount hose clamps  Hose clamp pliers (60029057000) ( p. 214) 302608-11 – Position the fuel pump. – Mount and tighten screws ...
Page 65: 09/Front Wheel
09/FRONT WHEEL Removing the front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 9) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. 800078-10 – Remove screw ...
Page 66: Checking The Tire Air Pressure
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 67: 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 five years. »...
Page 68: 10/Rear Wheel
10/REAR WHEEL Removing rear wheel 13.1 – Raise the motorcycle with the lift stand. ( p. 9) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. – Remove nut .
Page 69: Checking The Chain Tension
10/REAR WHEEL – Tighten nut  Guideline Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. –...
Page 70: Adjusting Chain Guide
10/REAR WHEEL – 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 ...
Page 71: Cleaning The Chain
10/REAR WHEEL – Shift into neutral; pull the lower chain section with specified weight  Guideline Weight of chain wear measurement 15 kg (33 lb.) – 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 72: Checking The Rear Hub Rubber Dampers
10/REAR WHEEL – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 210) – After drying, apply chain spray. Off-road chain spray ( p.
Page 73: Checking The Rim Run-Out
10/REAR WHEEL » If the spoke tensions differ: – Correct the spoke tension. Checking the rim run-out 13.10 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 74: 11/Wiring Harness, Battery
11/WIRING HARNESS, BATTERY Removing the battery 14.1 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
Page 75: 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 76: Checking The Charging Voltage
11/WIRING HARNESS, BATTERY – 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 77: Changing Fuses Of Individual Power Consumers
11/WIRING HARNESS, BATTERY – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 58) – Remove protection covers  600604-10 – Remove a defective main fuse with needle nose pliers.  – Install a new main fuse. Fuse (58011109130) ( p.
Page 78: Adjusting The Engine Characteristic
11/WIRING HARNESS, BATTERY Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Replace with a spare fuse of the right rating. Fuse (75011088010) ( p.
Page 79: 13/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 80 13/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 onto the brake disc by hand in order to push back the brake pistons.
Page 81: Checking The Free Travel Of The Hand Brake Lever
13/BRAKE SYSTEM Checking the free travel of the hand brake lever 15.3 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.
Page 82: Adding Front Brake Fluid
13/BRAKE SYSTEM Adding front brake fluid 15.6 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 83: Checking The Rear Brake Linings
13/BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
Page 84: Changing 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 85: Checking The Free Travel Of Foot Brake Lever
13/BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake   caliper support are seated correctly. 400419-10 – Insert the brake pads, insert the bolt and mount the split 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 86: Checking Rear Brake Fluid Level
13/BRAKE SYSTEM – Remove screws 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 87: Changing The Rear Brake Fluid
13/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 88 13/BRAKE SYSTEM – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( p. 208) – Mount the screw cap with the washer and membrane. – Activate the foot brake lever until there is a firm pressure point. Info Clean up overflowed or spilt brake fluid immediately with water.
Page 89: 14/Light System, Instruments
14/LIGHT SYSTEM, INSTRUMENTS Setting kilometers or miles 16.1 Info If you change the unit, the value ODO 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 in the position (690 Enduro EU, 690 Enduro AUS/UK) (690 Enduro USA).
Page 90: Combination Instrument - Setting/Resetting Trip 2
14/LIGHT SYSTEM, INSTRUMENTS Combination instrument - setting/resetting TRIP 2 16.4 Info The TRIP 2 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again.
Page 91: Checking The Headlight Setting
14/LIGHT SYSTEM, INSTRUMENTS Checking the headlight setting 16.6 – Stand the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...
Page 92: Installing The Headlight Mask With The Headlight
14/LIGHT SYSTEM, INSTRUMENTS Installing the headlight mask with the headlight 16.9 – Connect the connectors of headlight and flasher lights   – Check lighting function. 100294-11 – Remove the cloth from the fender, attach the headlight mask to points on the ...
Page 93: Changing The Headlight Bulb
14/LIGHT SYSTEM, INSTRUMENTS – 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 94 14/LIGHT SYSTEM, INSTRUMENTS – Mount the orange plug. – Position the diffuser. – Insert the screw and turn it first anticlockwise until it engages in the thread. Tighten the screw slightly. – Check the flasher system function.
Page 95: 30/Engine
30/ENGINE Removing the engine 17.1 – Raise the motorcycle with the work stand. ( p. 9) – Disconnect the battery. ( p. 72) – Remove the exhaust manifold. ( p. 51) – Drain the coolant. ( p. 154) – Loosen the spring-loaded band-type clamp using the special tool.
Page 96 30/ENGINE – Take off the clutch push rod. – Unscrew the electrical connection from the starter motor.  – Remove ground wire from the starter motor.  300216-10 – Loosen hose clip  – Pull off the throttle valve body from the rear. 300217-10 –...
Page 97: Installing The Engine
30/ENGINE – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 218) 300222-10 – Remove nut of the lower engine bracket. Remove the screw.  300223-10 – Remove screw of the swingarm pivot.
Page 98 30/ENGINE – Install the screw and nut of the lower engine bracket, but do not tighten them  yet. 300223-11 – Remove the floor jack with the special tool. Floor jack attachment (75029055000) ( p. 218) 300222-10 – Position the engine bearer. –...
Page 99 30/ENGINE – Reconnect plug connectors of the gear position sensor, the crankshaft position  sensor and the alternator. 300218-11 – Position the throttle valve body. – Position and tighten hose clip  300217-11 – Position the electrical connection on the starter motor. Mount and tighten screw. ...
Page 100 Remove the motorcycle from the work stand. ( p. 10) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p.
Page 101: 30/Disassembling The Engine
30/DISASSEMBLING THE ENGINE Clamping engine into engine work stand 18.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 215) Support for engine work stand (75012001060) ( p. 215) Holder for engine work stand (75012001070) ( p.
Page 102: Removing The Alternator Cover
30/DISASSEMBLING THE ENGINE Removing the alternator cover 18.5 – Remove screws . Take off the alternator cover.  – Remove dowels. 300004-10 Removing spacer 18.6 – Remove the spacer of the countershaft.  302124-10 Removing gear position sensor 18.7 – Remove screws.
Page 103: Removing Thermostat
30/DISASSEMBLING THE ENGINE – Remove screws. Remove the oil filter cover with the O-ring.  – Pull the oil filter element out of the oil filter case.  Circlip pliers reverse (51012011000) ( p. 212) 300011-10 Removing thermostat 18.9 – Remove screws.
Page 104: Removing Clutch Cover
30/DISASSEMBLING THE ENGINE – Remove screw . Take off the water pump wheel   – Take off the water pump cover seal. Info Do not lose the centering pins. 300013-10 – Remove the shaped washer  300014-10 Removing clutch cover 18.12 –...
Page 105: Removing Timing Chain Tensioner
30/DISASSEMBLING THE ENGINE Removing timing chain tensioner 18.15 – Remove screw . Take off the seal ring.  – Pull out timing chain tensioner  300017-10 Removing camshafts 18.16 – Remove screw . Take off the camshaft support plate  ...
Page 106: Removing Rotor
30/DISASSEMBLING THE ENGINE – Remove piston pin retainer  – Remove the piston pin. – Take off the cylinder with the piston. – Push the piston upward out of the cylinder. Info If no other work is required on the cylinder and the piston, you can leave the piston in the cylinder.
Page 107: Removing Timing Chain And Timing Chain Sprocket
30/DISASSEMBLING THE ENGINE – Hold the timing chain securing guide tight and pull the timing chain tensioning rail out of the timing chain securing guide.  – Take out the timing chain tensioning rail upwards through the chain shaft. – Remove the timing chain securing guide ...
Page 108 30/DISASSEMBLING THE ENGINE – Loosen the screws diagonally and remove them with their spring retainers and  clutch springs. – Remove the pressure cap  300052-10 – Remove the pressure piece  – Bend up the lock washer  300053-10 –...
Page 109: Removing Primary Gear
30/DISASSEMBLING THE ENGINE Removing primary gear 18.24 – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p. 219) – Screw the special tool on to the primary gear   Extractor (75029021000) ( p. 216) – Hold it using the special tool and pull off the primary gear by turning the screw in. –...
Page 110: Removing Locking Lever
30/DISASSEMBLING THE ENGINE Removing locking lever 18.28 – Remove screw  – Take off locking lever with the sleeve and spring.  300069-10 Removing oil pumps 18.29 – Remove the lock washers and normal washers from both oil pumps.  ...
Page 111: Removing Crankshaft And Balancer Shaft
30/DISASSEMBLING THE ENGINE – Install the special tool with suitable screws.  Extractor (75029048000) ( p. 217) 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 112 30/DISASSEMBLING THE 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 113: 30/Engine - Work On Individual Parts
30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 19.1 – Remove oil jet  – Remove bearing locks of the main shaft bearing , of the countershaft bearing   and of the shift drum bearing ...
Page 114: Work On The Left Section Of The Engine Case
30/ENGINE - WORK ON INDIVIDUAL PARTS Guideline Oil jet, conrod lubrication 2 Nm Loctite ® 243™ (1.5 lbf ft) – Blow compressed air through all oil holes and check that they are clear. – Position the cover plate . Mount and tighten the screws. ...
Page 115: Work On The Clutch Cover
30/ENGINE - WORK ON INDIVIDUAL PARTS Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in. –...
Page 116: Removing Crankshaft Bearing Inner Ring
30/ENGINE - WORK ON INDIVIDUAL PARTS Removing crankshaft bearing inner ring 19.4 – Fix the crankshaft with special tools in the vise.   Upper part, pressing-out tool (75029047050) ( p. 217) Under part, pressing-out tool (75029047051) ( p. 217) 300135-10 –...
Page 117 30/ENGINE - WORK ON INDIVIDUAL PARTS – Press in the new crank pin as far as possible.  Info The crank pin must be pressed in so that oil hole is aligned with oil  hole  If the oil holes are not correctly aligned, the conrod bearing will not be sup- plied with oil.
Page 118: Checking Crankshaft Run-Out At Bearing Pin
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking crankshaft run-out at bearing pin 19.7 – Position the crankshaft on a roller block. – Rotate the crankshaft slowly. – Check the crankshaft run-out at both bearing pins. ≤ 0.10 mm (≤ 0.0039 in) Crankshaft run-out at bearing pin »...
Page 119: Measuring Axial Clearance Of Crankshaft And Balancer Shaft
30/ENGINE - WORK ON INDIVIDUAL PARTS Measuring axial clearance of crankshaft and balancer shaft 19.10 – Insert the crankshaft and balancer shaft in the right engine casing. Info Do not forget the dowels. – Mount the left engine casing. – Mount and tighten the screws.
Page 120: Checking/Measuring The Cylinder
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking/measuring the cylinder 19.12 – 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. »...
Page 121: Checking Piston Ring End Gap
30/ENGINE - WORK ON INDIVIDUAL PARTS – Clean the piston ring groove. 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. Info Mount the piston ring with the marking facing upward.
Page 122: Checking Piston/Cylinder Mounting Clearance
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking piston/cylinder mounting clearance 19.15 – Check/measure the cylinder. ( p. 118) – Check/measure the piston. ( p. 118) – The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam- eter.
Page 123: Preparing Timing Chain Tensioner For Installation
30/ENGINE - WORK ON INDIVIDUAL PARTS – When assembling, first connect the autodecompression spring and then insert the screw through the autodecompression weight. The arm of the autodecompression spring is long enough to pass right  through the autodecompression weight. –...
Page 124: Checking Timing Assembly
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking timing assembly 19.19 – Clean all parts well. 0 0 1 0 0 5 – Check the timing chain gear / timing chain sprocket for damage and wear.  » If there is damage or wear: –...
Page 125: Removing Valves
30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove the small camshaft bearing using the special tool.  Insert for bearing puller (15112018100) ( p. 212) Bearing puller (15112017000) ( p. 212) 300228-10 – Press in the small camshaft bearing as far as possible using the special tool ...
Page 126: Checking Valves
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking valves 19.23 – Check the run-out at the valve plate. Valve - run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate » If the measured value does not equal the specified value: –...
Page 127: Installing Valves
30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 214) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion »...
Page 128: Installing Rocker Arm
30/ENGINE - WORK ON INDIVIDUAL PARTS Installing rocker arm 19.28 – 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.
Page 129: Checking The Clutch
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the clutch 19.30 – Dismantle the antihopping clutch. ( p. 126) 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...
Page 130: Preassembling Antihopping Clutch
30/ENGINE - WORK ON INDIVIDUAL PARTS » If the intermediate discs are not level or are pitted: – Replace all intermediate discs. – Check clutch facing discs for discoloration and scoring.  » If there is discoloration or scoring: – Change all clutch facing discs.
Page 131: Checking Shift Mechanism
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking shift mechanism 19.32 – 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 the idler/fixed gear pair. 0 0 4 0 0 1 –...
Page 132: Disassembling The Main Shaft
30/ENGINE - WORK ON INDIVIDUAL PARTS Disassembling the main shaft 19.34 0303 300127-03 – 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  ...
Page 133: Checking The Transmission
30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove stop disk and the first-gear idler gear   – Remove needle bearing and stop disk   – Remove the fifth-gear sliding gear and lock ring   – Remove stop disk and the third-gear idler gear ...
Page 134: Assembling The Main Shaft
30/ENGINE - WORK ON INDIVIDUAL PARTS » If the fixed gear does not move easily: – Change the fixed gear or the main shaft. – Check fixed gears for smooth operation in the profile of countershaft   » If the fixed gear does not move easily: –...
Page 135: Assembling Countershaft
30/ENGINE - WORK ON INDIVIDUAL PARTS Assembling countershaft 19.38 Info Use new lock rings in every repair job. – Oil all parts carefully before assembling. – Check the transmission. ( p. 131) 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –...
Page 136: Checking Electric Starter Drive
30/ENGINE - WORK ON INDIVIDUAL PARTS Checking electric starter drive 19.39 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. –...
Page 137: Checking Freewheel
30/ENGINE - WORK ON INDIVIDUAL PARTS – Compress the expansion ring and remove it, using suitable pliers.  – Take the freewheel out of the primary gear.  300128-10 Checking freewheel 19.41 – Insert the freewheel gear in the primary gear , turning the primary gear clock- ...
Page 138 30/ENGINE - WORK ON INDIVIDUAL PARTS – Insert the lock ring into the groove with suitable pliers and check that it is  seated correctly. 300127-11...
Page 139: 30/Assembling The Engine
30/ASSEMBLING THE ENGINE Installing transmission shafts 20.1 – Clamp the right section of the engine case. Holder for engine work stand (75012001070) ( p. 215) Support for engine work stand (75012001060) ( p. 215) Engine work stand (61229001000) ( p. 215) –...
Page 140: Installing Crankshaft And Balancer Shaft
30/ASSEMBLING THE ENGINE Installing crankshaft and balancer shaft 20.2 – Mount the special tool on the alternator side of the crankshaft.  Mounting sleeve (75029080000) ( p. 218) – Mount the special tool on the balancer shaft.  Mounting sleeve (58529005000) ( p.
Page 141: Installing Oil Pumps
30/ASSEMBLING THE ENGINE Installing oil pumps 20.4 – Install pins and internal rotors on both oil pump shafts. – Mount external rotors in the engine case. The marking is not visible after mounting. – Mount the oil pump shafts with internal rotors ...
Page 142: Installing Shift Shaft
30/ASSEMBLING THE ENGINE – Release the locking lever. – Mount and tighten screw  Guideline Screw, shift drum locating 10 Nm Loctite ® 243™ (7.4 lbf ft) 300067-11 Installing shift shaft 20.7 – Slide shift shaft with the washer into the bearing seat. ...
Page 143: Installing Clutch Cage
30/ASSEMBLING THE ENGINE Installing clutch cage 20.10 – Install supporting plate and needle bearing   300057-10 – Install the clutch cage  Info Turn the clutch cage and oil pump gear wheels backwards and forwards slightly to help them mesh more easily. –...
Page 144: Installing Crankshaft Position Sensor
30/ASSEMBLING THE ENGINE – Insert the pressure piece  300061-10 – Place the pressure cap on. – Install and tighten the screws with the spring retainers and clutch springs.  Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) – Remove the special tool.
Page 145: Installing Timing Chain Rails
30/ASSEMBLING THE ENGINE Installing timing chain rails 20.13 – Position the timing chain securing guide  Info The cable of the crankshaft position sensor must be laid in the cable chan- nel of the timing chain securing guide. – Thread in the timing chain tensioning rail from above.
Page 146: Setting Engine To Top Dead Center
30/ASSEMBLING THE ENGINE Setting engine to top dead center 20.16 – Set the crankshaft to top dead center and lock it with the special tool  Engine blocking screw (77329010000) ( p. 219) 300025-10 Installing piston 20.17 – Shift the joint of the piston rings by 120°. –...
Page 147: Installing Cylinder Head
30/ASSEMBLING THE ENGINE – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. Info For clarity, the following steps are illustrated using a disassembled piston. 300036-10 – Position the piston pin retainer. 400366-10 –...
Page 148: Installing Camshafts
30/ASSEMBLING THE ENGINE Guideline Cylinder head screw Tightening Lubricated with sequence: engine oil Tighten diag- onally, begin- ning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft)
Page 149: Checking Valve Clearance
30/ASSEMBLING THE ENGINE – Remove screw and use the special tool to push the timing chain tensioner  toward the timing chain. Release device for timing chain tensioner (77329051000) ( p. 220) The timing chain tensioner unlocks. – Mount and tighten screw ...
Page 150: Installing Spark Plug
30/ASSEMBLING THE ENGINE – Remove shims and set them down according to the installation position.  – Correct the shims as indicated by the results of the valve clearance check. – Insert suitable shims. – Position the rocker arms and push in the rocker arm shafts. Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards.
Page 151: Mounting Water Pump Cover
30/ASSEMBLING THE ENGINE Mounting water pump cover 20.26 – Push on the shaped washer  300014-11 – Attach the water pump wheel . Mount and tighten screw   Guideline Screw, water pump wheel 10 Nm Loctite ® 243™ (7.4 lbf ft) Loctite ®...
Page 152: Installing Gear Position Sensor
30/ASSEMBLING THE ENGINE – Insert the oil filter  – Lubricate the O-ring of the oil filter cover. Install the oil filter cover  – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 300011-11 Installing gear position sensor 20.29...
Page 153: Installing Oil Screens
30/ASSEMBLING THE ENGINE Installing oil screens 20.31 – Push the oil screen with O-rings on to a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case.
Page 154: Installing Starter Motor
30/ASSEMBLING THE ENGINE – Remove special tool  Engine blocking screw (77329010000) ( p. 219) – Mount and tighten screw  Guideline Plug, crankshaft location 20 Nm (14.8 lbf ft) 300024-11 Installing starter motor 20.33 – Grease O-ring. Mount the starter motor. Long-life grease ( p.
Page 155: 32/Clutch
32/CLUTCH Checking/rectifying the fluid level of the hydraulic clutch 21.1 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 156: 35/Water Pump, Cooling System
35/WATER PUMP, COOLING SYSTEM Draining coolant 22.1 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 157: Checking The Antifreeze And Coolant Level
35/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 poisonous and inhaling them may result in unconsciousness and/or death.
Page 158: Checking The Coolant Level
35/WATER PUMP, COOLING SYSTEM – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p. 208) Alternative 2 Coolant (mixed ready to use) ( p. 208) – Mount the radiator cap. Checking the coolant level 22.4 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
Page 159: 38/Lubrication System
38/LUBRICATION SYSTEM Oil circuit 23.1 400500-60 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 Crankshaft Oil screen Suction pump Transmission Checking the engine oil level 23.2 Info The engine oil level must be checked when the engine is warm.
Page 160: Checking The Engine Oil Pressure
38/LUBRICATION SYSTEM – 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 161: Changing The Engine Oil And Filter, Cleaning The Oil Screens
38/LUBRICATION SYSTEM – Change the oil filter. Check the oil pumps for wear. Check that all oil holes are clear. – 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.
Page 162: Removing The Oil Filter
38/LUBRICATION SYSTEM – Thoroughly clean the oil drain plug with a magnet. – Refit 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 Removing the oil filter 23.6 Warning...
Page 163: Cleaning The Oil Screens
38/LUBRICATION SYSTEM Cleaning the oil screens 23.8 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 164: Filling Up With Engine Oil
38/LUBRICATION SYSTEM Filling up with engine oil 23.9 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – 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) (00062010035) (...
Page 165: 39/Ignition System
39/IGNITION SYSTEM Alternator - checking the stator winding 24.1 Condition The stator is disconnected. – Reinstall the fuel tank. Stator winding, measurement I - check the resistance – Measure the resistance between the specified points. Stator, connector EN pin 1 – Stator, connector EN pin 2 Alternator ≤...
Page 166: Ignition Coil - Checking The Secondary Winding
39/IGNITION SYSTEM Ignition coil - checking the secondary winding 24.3 Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. – Remove the fuel tank. Ignition coil cylinder 1 - check the secondary winding resistance –...
Page 167: 41/Throttle Valve Body
– Press "Continue". – Read the information page in the KTM diagnostics tool and use "Continue" to open the "Check the throttle position sensor circuit A position" menu. The motor drive moves the throttle valve to the basic position (completely closed).
Page 168: Adjusting The Basic Setting Of The Motor Drive
Select "Adjusting the basic setting of the motor drive". – Press "Continue". – Read the information page in the KTM diagnostics tool and use "Continue" to open the "Adjusting the position of the throttle position sensor in circuit A" menu. 400786-60...
Page 169 41/THROTTLE VALVE BODY – Carefully close the throttle valve with your finger and hold it. – Check the voltage value. Info The "Continue" button only appears if the measured value equals the set- point value. Throttle position sensor circuit A Basic position - voltage "THAD"...
Page 170 41/THROTTLE VALVE BODY Loctite ® 648™ Info Tighten by hand only, do not use a tool. – Press "Continue". – Open and close the throttle grip fully ten times. The "Continue" button appears. – Press "Continue". – Check the voltage value. Info The "Continue"...
Page 171: Flashing The Efi Control Unit And/Or The Ept Control Unit
Fix screws with locking varnish.  – Press "Continue". – Read the information page on the KTM diagnostics tool and, using "Continue", start the "ECU Reset" menu. The control unit is reset. – Complete the procedure with "Continue". – Switch off the ignition by turning the ignition key in the position (690 Enduro EU, 690 Enduro AUS/UK) (690 Enduro USA).
Page 172: Requesting The Enabling Code
Select "Change VIN - New identity". 400687-60 – Press "Continue". – Read the information page on the KTM diagnostics tool and, using "Continue", start the coding process. – Overwrite the entry under "Please enter VIN:" with the new chassis number. Info For used control units, the chassis number programmed last is displayed.
Page 173: Coding The Efi Control Unit And/Or Ept Control Unit
– Select "Change VIN - New identity". – Press "Continue". – Read the information page on the KTM diagnostics tool and using "Continue" start the coding process. – Under "Please enter VIN:" enter the new VIN. Info For new control units, a sample VIN is displayed.
Page 174 41/THROTTLE VALVE BODY – Switch to the main menu. – Select "Show identification". – Compare the old VIN to the new VIN. The new VIN is shown.
Page 175: Technical Data - Engine
TECHNICAL DATA - 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 176: Technical Data - Tolerance, Wear Limits Of Engine
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Camshafts - diameter, bearing pin ≥ 39.95 mm (≥ 1.5728 in) Next to exhaust cam ≥ 17.96 mm (≥ 0.7071 in) Next to inlet cam Valve spring Minimum length (without valve spring cap) 42.3 mm (1.665 in) Valve spring cap - thickness 2.4…...
Page 177 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Main shaft axial clearance 0.10… 0.40 mm (0.0039… 0.0157 in) ≤ 0.025 mm (≤ 0.00098 in) Transmission shaft run-out Shift shaft - play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in) Fuel pressure Under every load condition 3.3…...
Page 178: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite...
Page 179 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug M12x1.25 17 Nm (12.5 lbf ft) –...
Page 180: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder-coated WP Suspension 4860 MXMA Fork Shock absorber WP Suspension 4618 with Pro‑Lever deflector 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...
Page 181: Capacity - Fuel
90/90 - 21 M/C 54R TT 130/90 - 18 M/C 69R TT Pirelli MT 21 RALLYCROSS Pirelli MT 21 RALLYCROSS Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 29.2 Total fuel tank capacity, 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.
Page 182: Technical Data - Fork
TECHNICAL DATA - FORK Fork part number 14.18.7D.11 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) 472 mm (18.58 in)
Page 183: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7D.11 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport...
Page 184: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, combination instrument holder EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft)
Page 185 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, spring holder on side stand 25 Nm (18.4 lbf ft) Loctite 243™ bracket ® Screw, steering stem 20 Nm (14.8 lbf ft) Loctite 243™ – Screw, top triple clamp 17 Nm (12.5 lbf ft) –...
Page 186: Cleaning/Protective Treatment
CLEANING/PROTECTIVE TREATMENT Cleaning the motorcycle 33.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 187: Protective Treatment For Winter Operation
CLEANING/PROTECTIVE TREATMENT Protective treatment for winter operation 33.2 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. Warm water would enhance the corrosive effects of salt. –...
Page 188: Storage
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 9) –...
Page 189: 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 190: Wiring Diagram
WIRING DIAGRAM Page 1 of 10 36.1 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 600974-01...
Page 191 WIRING DIAGRAM EFI control unit Fuse Battery Generator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator X291 Connector for accessory ground (terminal 31) ACC 1 (not assigned) X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)
Page 192: 190
WIRING DIAGRAM Page 2 of 10 36.2 ye-rd bl-rd ye-rd ye-rd ye-rd wh-rd wh-rd wh-rd wh-rd br-gr br-gr wh-rd ye-rd wh-bl wh-bl ye-rd wh-rd ye-rd ye-rd 600975-01...
Page 193 WIRING DIAGRAM 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 194: 192
WIRING DIAGRAM Page 3 of 10 36.3 ye-bu ye-bu 600976-01...
Page 195 WIRING DIAGRAM Low beam, high beam Fuse Fuse Combination instrument Horn Parking light High beam/low beam switch, horn button, turn signal switch...
Page 196: 194
WIRING DIAGRAM Page 4 of 10 36.4 wh-gn ye-bu wh-gn ye-bu wh-gn 600977-01...
Page 197 WIRING DIAGRAM Front brake light switch Brake light switch, rear License plate lamp Brake/tail light...
Page 198: 196
WIRING DIAGRAM Page 5 of 10 36.5 bl-or ye-bu bl-or 600978-01...
Page 199 WIRING DIAGRAM 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 200: 198
WIRING DIAGRAM Page 6 of 10 36.6 bl-rd bl-rd wh-bl wh-bl 600979-01...
Page 201 WIRING DIAGRAM 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 202: 200
WIRING DIAGRAM Page 7 of 10 36.7 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 600980-01...
Page 203 WIRING DIAGRAM EFI control unit EPT control unit Fuse Fuse Fuse Fuel pump Motor drive Combination instrument X295 Diagnostics connector...
Page 204: 202
WIRING DIAGRAM Page 8 of 10 36.8 bl-or bl-or rd-gr rd-gr bl-gr bl-gr wh-pu wh-pu gn-rd gn-rd wh-bu wh-bu bu-br bu-br bl-or bl-or 600981-01...
Page 205 WIRING DIAGRAM 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 206: 204
WIRING DIAGRAM Page 9 of 10 36.9 ye-gn ye-gn wh-pk wh-pk ye-or ye-or ye-br ye-br bl-gn bl-gn bl-gn 600982-01...
Page 207 WIRING DIAGRAM 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 208: 206
WIRING DIAGRAM Page 10 of 10 36.10 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 600983-01...
Page 209 WIRING DIAGRAM 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 Black Brown Blue Green Gray Light blue Orange Pink Violet...
Page 210: Substances
– 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 – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
Page 211 – 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 – Hydraulic Fluid 75...
Page 212: Auxiliary Substances
AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and preserving materials for metal, rubber and plastic Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Protect & Shine 645...
Page 213 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 products.
Page 214: 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 215 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 216 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 400110-01 Hose clamp pliers Art. no.: 60029057000 400142-01 Pliers for spring-loaded band-type clamp Art. no.: 60029057100 400085-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01...
Page 217 SPECIAL TOOLS Engine work stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01 Support for engine work stand Art. no.: 75012001060 400153-01 Holder for engine work stand Art. no.: 75012001070 400154-01 Piston assembly ring Art. no.: 75029015102 400156-01...
Page 218 SPECIAL TOOLS Extractor Art. no.: 75029021000 400157-01 Assembly screws Art. no.: 75029033000 400158-01 Piston pin lock ring insert Art. no.: 75029035000 400160-01 Work stand adapter Art. no.: 75029036000 400161-01 Push-in drift Art. no.: 75029044010 500163-01...
Page 219 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 220 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 221 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 222 SPECIAL TOOLS Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Valve spring mounting device Art. no.: 78029060000 500165-01 Spring compressor Art. no.: T101S 300573-10 Hook wrench Art. no.: T106S 301085-01 Art. no.: T120 201235-10...
Page 223 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 224 SPECIAL TOOLS 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 Clamping stand Art. no.: T1403S 200637-10...
Page 225 SPECIAL TOOLS Mounting sleeve Art. no.: T1515 300569-10 Filling adapter Art. no.: T1516 300567-10 Hook wrench Art. no.: T157S 200899-10 Art. no.: T605 200687-10...
Page 226: 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 227: Index
INDEX front brake, changing ......80 INDEX rear brake, adding ......84 Accessories .
Page 228 INDEX oil pumps, removing ......108 rocker arm, removing ..... . . 122 piston, removing .
Page 229 INDEX removing ....... . . 14 installing ....... . 160 tap compression, assembling .
Page 230 INDEX removing ....... . . 58 Spare parts ........6 Spark plug connector checking .
Page 231 *3206041en* 3206041en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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KTM 690 Enduro EU 2008 Repair Manual

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