KTM 690 Enduro R USA 2012 Manuals

Manuals and User Guides for KTM 690 Enduro R USA 2012. We have 1 KTM 690 Enduro R USA 2012 manual available for free PDF download: Repair Manual

KTM 690 Enduro R USA 2012 Repair Manual

KTM 690 Enduro R USA 2012 Repair Manual (234 pages)

Brand: KTM | Category: Motorcycle | Size: 12.36 MB

Table of Contents

Table of Contents
4
1 Means of Representation

7
- Symbols Used
  7
- Formats Used
  7
2 Safety Advice

8
- Repair Manual
  8
- Degrees of Risk and Symbols
  8
- Work Rules
  8
3 Important Notes

9
4 Serial Numbers

10
- Chassis Number
  10
- Type Label
  10
- Engine Number
  10
- Key Number
  10
- Fork Part Number
  10
- Shock Absorber Part Number
  11
5 Motorcycle

12
6 Fork, Triple Clamp

15
7 Handlebar, Controls

35
8 Frame

38
- Removing the Engine Guard
  38
- Installing the Engine Guard
  38
9 Shock Absorber, Swingarm

39
10 Exhaust

58
- Removing the Manifold
  58
- Installing the Manifold
  58
- Removing the Main Silencer
  59
- Installing the Main Silencer
  60
11 Air Filter

61
12 Fuel Tank, Seat, Trim

64
- Opening the Filler Cap
  64
- Closing Filler Cap
  64
- Removing the Seat
  64
- Mounting the Seat
  65
- Taking off the Side Cover
  65
- Mounting the Side Cover
  65
- Checking the Fuel Pressure
  66
- Changing the Fuel Filter
  67
- Changing the Fuel Pump
  70
13 Wheels

73
14 Wiring Harness, Battery

84
- Removing the Battery
  84
- Installing the Battery
  84
- Disconnecting the Battery
  84
- Connecting the Battery
  85
- Recharging the Battery
  85
- Checking the Charging Voltage
  86
- Changing the Main Fuse
  87
- Changing Fuses of Individual Power Consumers
  87
- Adjusting the Engine Characteristic
  88
15 Brake System

90
16 Lighting System, Instruments

100
- Combination Instrument
  100
- Setting Kilometers or Miles
  100
- Setting the Clock
  100
- Setting/Resetting Display TRIP 1
  100
- Setting/Resetting Display TRIP 2
  100
- Setting the Wheel Circumference
  101
- Checking the Headlight Setting
  102
- Adjusting the Headlight Range
  102
- Removing the Headlight Mask with the Headlight
  102
- Installing the Headlight Mask with the Headlight
  103
- Changing the Parking Light Bulb
  103
- Changing the Headlight Bulb
  104
- Changing the Turn Signal Bulb
  104
17 Engine

106
- Removing the Engine
  106
- Installing the Engine
  108
- Engine Disassembly
  112
- Clamping the Engine into the Engine Assembly Stand
  112
- Draining the Engine Oil
  112
- Removing Starter Motor
  113
- Removing Valve Cover
  113
- Removing the Alternator Cover
  113
- Removing Spacer
  113
- Removing Gear Position Sensor
  113
- Removing Oil Filter
  114
- Removing Thermostat
  114
- Setting Engine to Ignition Top Dead Center
  114
- Removing Water Pump Wheel
  115
- Removing Clutch Cover
  115
- Removing Spacer and Spring
  116
- Removing Spark Plug
  116
- Removing Timing Chain Tensioner
  116
- Removing Camshafts
  116
- Removing Cylinder Head
  117
- Removing Piston
  117
- Removing Rotor
  117
- Removing Timing Chain Rails
  118
- Removing Timing Chain and Timing Chain Sprocket
  118
- Removing Crankshaft Position Sensor
  119
- Removing Clutch Cage
  119
- Removing Primary Gear
  120
- Removing Starter Drive
  120
- Removing Shift Shaft
  121
- Removing Shift Drum Locating
  121
- Removing Locking Lever
  121
- Removing Oil Pumps
  121
- Removing Left Engine Case
  122
- Removing Crankshaft and Balancer Shaft
  122
- Removing Transmission Shafts
  123
- Work on Individual Parts
  124
- Work on the Right Section of the Engine Case
  124
- Work on the Left Section of the Engine Case
  125
- Work on the Clutch Cover
  127
- Removing Crankshaft Bearing Inner Ring
  127
- Removing Balancer Shaft Drive Wheel
  127
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin
  127
- Checking Crankshaft Run-Out at Bearing Pin
  129
- Installing Balancer Shaft Drive Wheel
  129
- Installing Crankshaft Bearing Inner Ring
  130
- Measuring Axial Clearance of Crankshaft and Balancer Shaft
  130
- Cylinder - Nikasil ® Coating
  131
- Checking/Measuring the Cylinder
  131
- Checking/Measuring the Piston
  132
- Checking Piston Ring End Gap
  133
- Checking Piston/Cylinder Mounting Clearance
  133
- Checking Oil Pumps for Wear
  133
- Replacing Autodecompressor
  134
- Preparing Timing Chain Tensioner for Installation
  134
- Checking Timing Assembly
  135
- Removing Rocker Arm
  135
- Changing Camshaft Bearing
  136
- Removing Valves
  137
- Checking Valves
  137
- Checking Valve Springs
  138
- Checking Valve Spring Retainer
  138
- Checking Cylinder Head
  138
- Installing Valves
  139
- Installing Rocker Arm
  139
- Disassembling the Antihopping Clutch
  140
- Checking the Clutch
  140
  - Preassembling the Antihopping Clutch
    142
  - Checking Shift Mechanism
    143
  - Preassembling Shift Shaft
    143
  - Disassembling the Main Shaft
    144
  - Dismantling Countershaft
    144
  - Checking the Transmission
    145
  - Assembling the Main Shaft
    146
  - Assembling Countershaft
    147
  - Checking the Starter Drive
    148
  - Removing Freewheel
    148
  - Checking Freewheel
    149
  - Installing Freewheel
    149
  - Engine Assembly
    150
  - Installing Transmission Shafts
    150
  - Installing Crankshaft and Balancer Shaft
    151
  - Installing Left Engine Case
    152
  - Installing Oil Pumps
    152
  - Installing Locking Lever
    153
  - Installing Shift Drum Locating
    153
  - Installing Shift Shaft
    153
  - Installing Starter Drive
    153
  - Installing Primary Gear
    154
  - Clutch Cage, Installing
    154
  - Installing Crankshaft Position Sensor
    155
  - Installing Timing Chain and Timing Chain Sprocket
    156
  - Installing Timing Chain Rails
    156
  - Installing Rotor
    156
  - Adjusting Crankshaft Position Sensor Distance
    157
  - Setting Engine to Top Dead Center
    157
  - Installing Piston
    157
  - Installing Cylinder Head
    159
  - Installing Camshafts
    159
  - Installing Timing Chain Tensioner
    160
  - Checking Valve Clearance
    160
  - Adjusting Valve Clearance
    161
  - Installing Spark Plug
    162
  - Installing Spacer and Spring
    162
  - Installing Clutch Cover
    162
  - Mounting Water Pump Cover
    162
  - Installing Thermostat
    163
  - Installing the Oil Filter
    163
  - Installing Gear Position Sensor
    163
  - Installing the Spacer
    164
  - Installing Oil Screens
    164
  - Installing Alternator Cover
    165
  - Installing the Starter Motor
    165
  - Installing Valve Cover
    166
  - Removing the Engine from the Engine Assembly Stand
    166
18 Clutch

167
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch
  167
- Changing the Hydraulic Clutch Fluid
  167
19 Water Pump, Cooling System

168
- Draining the Coolant
  168
- Filling/Bleeding the Cooling System
  168
- Checking the Antifreeze and Coolant Level
  169
- Checking the Coolant Level
  170
20 Lubrication System

171
- Oil Circuit
  171
- Checking the Engine Oil Level
  171
- Checking the Engine Oil Pressure
  172
- Changing the Engine Oil and Filter, Cleaning the Oil Screens
  173
- Draining the Engine Oil
  173
- Removing the Oil Filter
  174
- Installing the Oil Filter
  174
- Cleaning the Oil Screens
  175
- Filling up with Engine Oil
  176
- Adding Engine Oil
  176
21 Ignition System

177
22 Technical Data

179
- Engine
  179
- Engine Tolerance, Wear Limits
  179
- Engine Tightening Torques
  181
- Capacities
  182
- Engine Oil
  182
- Coolant
  182
- Fuel
  182
- Chassis
  182
- Electrical System
  183
- Tires
  183
- Fork
  184
- Shock Absorber
  184
- Chassis Tightening Torques
  185
23 Cleaning/Protective Treatment

187
- Cleaning the Motorcycle
  187
- Checks and Maintenance Steps for Winter Operation
  188
24 Storage

189
- Preparing for Use after Storage
  189
25 Service Schedule

190
26 Wiring Diagram

192
- 190
  192
- 192
  194
- 194
  196
- 196
  198
- 198
  200
- 200
  202
- 202
  204
- 204
  206
- 206
  208
- 208
  210
27 Substances

212
28 Auxiliary Substances

214
29 Special Tools

216
30 Standards

229
- Index
  230

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