KTM 690 Enduro EU 2009 Repair Manual page 5

CONTENTS
Adding front brake fluid ................................................. 89
Changing the front brake fluid ........................................ 89
Checking the rear brake linings ....................................... 90
Changing rear brake linings ............................................ 91
Checking the free travel of foot brake lever....................... 92
Adjusting the basic position of the foot brake lever ........... 92
Checking rear brake fluid level........................................ 93
Adding rear brake fluid .................................................. 93
Changing the rear brake fluid.......................................... 94
14/LIGHT SYSTEM, INSTRUMENTS ................................... 96
Setting kilometers or miles ............................................. 96
Setting the clock ........................................................... 96
Combination instrument - setting/resetting TRIP 1............ 97
Combination instrument - setting/resetting TRIP 2............ 97
Combination instrument - setting the wheel
circumference (690 Enduro)........................................... 98
Checking the headlight setting........................................ 98
Adjusting the headlight range ......................................... 99
Removing the headlight mask with the headlight .............. 99
Installing the headlight mask with the headlight ............. 100
Changing the parking light bulb .................................... 101
Changing the headlight bulb......................................... 102
Changing the turn signal bulb ....................................... 103
30/ENGINE..................................................................... 104
Removing the engine ................................................... 104
Installing the engine .................................................... 106
30/DISASSEMBLING THE ENGINE................................... 110
Clamping engine into engine work stand ........................ 110
Draining the engine oil ................................................. 110
Removing starter motor ................................................ 110
Removing valve cover................................................... 110
Removing the alternator cover....................................... 111
Removing spacer ......................................................... 111
Removing gear position sensor ...................................... 111
Removing oil filter ....................................................... 111
Removing thermostat ................................................... 112
Setting engine to ignition top dead center...................... 112
Removing water pump wheel ........................................ 112
Removing clutch cover ................................................. 113
Removing spacer and spring ......................................... 113
Removing spark plug ................................................... 113
Removing timing chain tensioner .................................. 114
Removing camshafts.................................................... 114
Removing cylinder head ............................................... 114
Removing piston.......................................................... 114
Removing rotor............................................................ 115
Removing timing chain rails ......................................... 115
Removing timing chain and timing chain sprocket .......... 116
Removing crankshaft position sensor ............................. 116
Removing clutch cage .................................................. 116
Removing primary gear................................................. 118
Removing starter drive ................................................. 118
Removing shift shaft .................................................... 118
Removing shift drum locating ....................................... 118
Removing locking lever ................................................ 119
Removing oil pumps .................................................... 119
Removing left engine case............................................ 119
Removing crankshaft and balancer shaft........................ 120
Removing transmission shafts....................................... 120
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 122
Work on the right section of the engine case .................. 122
Work on the left section of the engine case .................... 123
Work on the clutch cover .............................................. 124
Removing crankshaft bearing inner ring ......................... 125
Removing balancer shaft drive wheel ............................. 125
Changing the conrod bearing ........................................ 125
Checking crankshaft run-out at bearing pin .................... 127
Installing balancer shaft drive wheel.............................. 127
Installing crankshaft bearing inner ring.......................... 127
Measuring axial clearance of crankshaft and balancer
shaft .......................................................................... 128
Cylinder - Nikasil ® coating ............................................ 128
Checking/measuring the cylinder................................... 129
Checking/measuring the piston ..................................... 129
Checking piston ring end gap........................................ 130
Checking piston/cylinder mounting clearance ................. 131
Checking oil pumps for wear......................................... 131
Replacing autodecompressor ........................................ 131
Preparing timing chain tensioner for installation ............. 132
Checking timing assembly ............................................ 133
Removing rocker arm ................................................... 133
Changing camshaft bearing .......................................... 133
Removing valves.......................................................... 134
Checking valves........................................................... 135
Checking valve springs ................................................. 135
Checking valve spring retainer ...................................... 135
Checking cylinder head ................................................ 135
Installing valves .......................................................... 136
Installing rocker arm .................................................... 137
Dismantling antihopping clutch .................................... 137
Checking the clutch..................................................... 138
Preassembling antihopping clutch................................. 139
Checking shift mechanism ........................................... 140
Preassembling shift shaft ............................................. 140
Disassembling the main shaft ....................................... 141
Dismantling countershaft ............................................. 142
Checking the transmission............................................ 143
Assembling the main shaft ........................................... 145
Assembling countershaft .............................................. 146
Checking electric starter drive....................................... 147
Removing freewheel..................................................... 148
Checking freewheel...................................................... 148
Installing freewheel ..................................................... 149
30/ASSEMBLING THE ENGINE ........................................ 150
Installing transmission shafts ....................................... 150
Installing crankshaft and balancer shaft......................... 151
Installing left engine case ............................................ 151
Installing oil pumps ..................................................... 152
Installing locking lever ................................................. 152
Installing shift drum locating ........................................ 152
Installing shift shaft..................................................... 153
Installing starter drive .................................................. 153
Installing primary gear ................................................. 153
Installing clutch cage................................................... 154
Installing crankshaft position sensor.............................. 155
Installing timing chain and timing chain sprocket ........... 155
Installing timing chain rails .......................................... 156
Installing rotor............................................................. 156
Adjusting crankshaft position sensor distance................. 156
Setting engine to top dead center.................................. 157
Installing piston .......................................................... 157
Installing cylinder head ................................................ 158
Installing camshafts .................................................... 159
Installing timing chain tensioner ................................... 159
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