KTM 690 enduro RAUS/UK Manuals

Manuals and User Guides for KTM 690 enduro RAUS/UK. We have 1 KTM 690 enduro RAUS/UK manual available for free PDF download: Repair Manual

KTM 690 enduro RAUS/UK Repair Manual

KTM 690 enduro RAUS/UK Repair Manual (235 pages)

2011

Brand: KTM | Category: Motorcycle | Size: 12.23 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

59
11 Air Filter

63
- Removing the Air Filter
  63
- Installing the Air Filter
  63
- Removing the Air Filter Box
  63
- Finishing Work
  63
- Installing the Air Filter Box
  64
- Mount the Side Cover
  65
- Mount the Seat
  65
12 Fuel Tank, Seat, Trim

66
- Opening the Filler Cap
  66
- Closing Filler Cap
  66
- Removing the Seat
  66
- Mounting the Seat
  67
- Taking off the Side Cover
  67
- Mounting the Side Cover
  67
- Checking the Fuel Pressure
  67
- Changing the Fuel Filter
  68
- Changing the Fuel Pump
  71
13 Wheels

75
14 Wiring Harness, Battery

86
- Removing the Battery
  86
- Installing the Battery
  86
- Disconnecting the Battery
  86
- Connecting the Battery
  87
- Recharging the Battery
  87
- Checking the Charging Voltage
  88
- Changing the Main Fuse
  89
- Changing Fuses of Individual Power Consumers
  89
- Adjusting the Engine Characteristic
  90
15 Brake System

92
16 Lighting System, Instruments

102
- Combination Instrument
  102
- Setting Kilometers or Miles
  102
- Setting the Clock
  102
- Setting/Resetting Display TRIP 1
  102
- Setting/Resetting Display TRIP 2
  102
- Setting the Wheel Circumference
  103
- Checking the Headlight Setting
  104
- Adjusting the Headlight Range
  104
- Removing the Headlight Mask with the Headlight
  104
- Installing the Headlight Mask with the Headlight
  105
- Changing the Parking Light Bulb
  105
- Changing the Headlight Bulb
  106
- Changing the Turn Signal Bulb
  106
17 Engine

108
- Removing the Engine
  108
- Installing the Engine
  110
- Engine Disassembly
  114
- Clamping the Engine into the Engine Assembly Stand
  114
- Draining the Engine Oil
  114
- Removing Starter Motor
  114
- Removing Valve Cover
  115
- Removing the Alternator Cover
  115
- Removing Spacer
  115
- Removing Gear Position Sensor
  115
- Removing Oil Filter
  116
- Removing Thermostat
  116
- Setting Engine to Ignition Top Dead Center
  116
- Removing Water Pump Wheel
  117
- Removing Clutch Cover
  117
- Removing Spacer and Spring
  117
- Removing Spark Plug
  118
- Removing Timing Chain Tensioner
  118
- Removing Camshafts
  118
- Removing Cylinder Head
  118
- Removing Piston
  119
- Removing Rotor
  119
- Removing Timing Chain Rails
  120
- Removing Timing Chain and Timing Chain Sprocket
  120
- Removing Crankshaft Position Sensor
  120
- Removing Clutch Cage
  121
- Removing Primary Gear
  122
- Removing Starter Drive
  122
- Removing Shift Shaft
  122
- Removing Shift Drum Locating
  122
- Removing Locking Lever
  123
- Removing Oil Pumps
  123
- Removing Left Engine Case
  123
- Removing Crankshaft and Balancer Shaft
  124
- Removing Transmission Shafts
  124
- Work on Individual Parts
  125
- Work on the Right Section of the Engine Case
  125
- Work on the Left Section of the Engine Case
  127
- Work on the Clutch Cover
  128
- Removing Crankshaft Bearing Inner Ring
  129
- Removing Balancer Shaft Drive Wheel
  129
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin
  129
- Checking Crankshaft Run-Out at Bearing Pin
  131
- Installing Balancer Shaft Drive Wheel
  131
- Installing Crankshaft Bearing Inner Ring
  131
- Measuring Axial Clearance of Crankshaft and Balancer Shaft
  132
- Cylinder - Nikasil ® Coating
  132
- Checking/Measuring the Cylinder
  133
- Checking/Measuring the Piston
  133
- Checking Piston Ring End Gap
  134
- Checking Piston/Cylinder Mounting Clearance
  134
- Checking Oil Pumps for Wear
  135
- Replacing Autodecompressor
  135
- Preparing Timing Chain Tensioner for Installation
  136
- Checking Timing Assembly
  136
- Removing Rocker Arm
  137
- Changing Camshaft Bearing
  137
- Removing Valves
  138
- Checking Valves
  138
- Checking Valve Springs
  139
- Checking Valve Spring Retainer
  139
- Checking Cylinder Head
  139
- Installing Valves
  140
- Installing Rocker Arm
  141
- Disassembling the Antihopping Clutch
  141
  - Checking the Clutch
    141
  - Preassembling the Antihopping Clutch
    143
  - Checking Shift Mechanism
    144
  - Preassembling Shift Shaft
    144
  - Disassembling the Main Shaft
    145
  - Dismantling Countershaft
    145
  - Checking the Transmission
    146
  - Assembling the Main Shaft
    147
  - Assembling Countershaft
    148
  - Checking the Starter Drive
    149
  - Removing Freewheel
    149
  - Checking Freewheel
    150
  - Installing Freewheel
    150
  - Engine Assembly
    151
  - Installing Transmission Shafts
    151
  - Installing Crankshaft and Balancer Shaft
    152
  - Installing Left Engine Case
    153
  - Installing Oil Pumps
    153
  - Installing Locking Lever
    154
  - Installing Shift Drum Locating
    154
  - Installing Shift Shaft
    154
  - Installing Starter Drive
    154
  - Installing Primary Gear
    155
  - Installing Clutch Cage
    155
  - Installing Crankshaft Position Sensor
    156
  - Installing Timing Chain and Timing Chain Sprocket
    157
  - Installing Timing Chain Rails
    157
  - Installing Rotor
    157
  - Adjusting Crankshaft Position Sensor Distance
    158
  - Setting Engine to Top Dead Center
    158
  - Installing Piston
    158
  - Installing Cylinder Head
    160
  - Installing Camshafts
    160
  - Installing Timing Chain Tensioner
    161
  - Checking Valve Clearance
    161
  - Adjusting Valve Clearance
    162
  - Installing Spark Plug
    163
  - Installing Spacer and Spring
    163
  - Installing Clutch Cover
    163
  - Mounting Water Pump Cover
    163
  - Installing Thermostat
    164
  - Installing the Oil Filter
    164
  - Installing Gear Position Sensor
    164
  - Installing the Spacer
    165
  - Installing Oil Screens
    165
  - Installing Alternator Cover
    166
  - Installing Starter Motor
    166
  - Installing Valve Cover
    167
  - Removing the Engine from the Engine Assembly Stand
    167
18 Clutch

168
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch
  168
- Changing the Hydraulic Clutch Fluid
  168
19 Water Pump, Cooling System

169
- Draining the Coolant
  169
- Filling/Bleeding the Cooling System
  169
- Checking the Antifreeze and Coolant Level
  170
- Checking the Coolant Level
  171
20 Lubrication System

172
- Lubrication System
  172
- Oil Circuit
  172
- Checking the Engine Oil Level
  172
- Checking the Engine Oil Pressure
  173
- Changing the Engine Oil and Filter, Cleaning the Oil Screens
  174
- Draining the Engine Oil
  174
- Removing the Oil Filter
  175
- Installing the Oil Filter
  175
- Cleaning the Oil Screens
  176
- Filling up with Engine Oil
  177
- Adding Engine Oil
  177
21 Ignition System

178
22 Technical Data

180
- Engine
  180
- Engine Tolerance, Wear Limits
  180
- Engine Tightening Torques
  182
- Capacities
  183
- Engine Oil
  183
- Coolant
  183
- Fuel
  183
- Chassis
  183
- Electrical System
  184
- Tires
  184
- Fork
  185
- Shock Absorber
  185
- Chassis Tightening Torques
  186
23 Cleaning/Protective Treatment

188
24 Storage

190
- Preparing for Use after Storage
  190
25 Service Schedule

191
26 Wiring Diagram

194
- 192
  194
- 194
  196
- 196
  198
- 198
  200
- 200
  202
- 202
  204
- 204
  206
- 206
  208
- 208
  210
- 210
  212
- Substances
  214
27 Substances

216
- Auxiliary Substances
  216
28 Auxiliary Substances

218
- Special Tools
  218
30 Standards

230
- Index
  231

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