KTM 690 ENDURO AUS/UK 2009 Motorcycle Manuals

Manuals and User Guides for KTM 690 ENDURO AUS/UK 2009 Motorcycle. We have 2 KTM 690 ENDURO AUS/UK 2009 Motorcycle manuals available for free PDF download: Repair Manual, Owner's Manual

KTM 690 ENDURO AUS/UK 2009 Repair Manual

KTM 690 ENDURO AUS/UK 2009 Repair Manual (265 pages)

Brand: KTM | Category: Motorcycle | Size: 13 MB

Table of Contents

Table of Contents

4
04/Shock Absorber, Swingarm

47
- Installing the Shock Absorber
  47
- Removing the Spring
  48
- Servicing the Shock Absorber
  48
- Dismantling the Damper
  49
- Disassembling the Piston Rod
  50
- Checking the Damper
  51
- Removing the Heim Joint
  52
- Installing the Heim Joint
  53
- Assembling the Piston Rod
  54
- Assembling the Damper
  55
- Guideline
  55
- Mount and Tighten Screw
  55
- Bleeding and Filling the Damper
  57
- Filling the Damper with Nitrogen
  59
- Installing the Spring
  60
- 05/Exhaust
  61
  - Removing the Exhaust Manifold
    61
  - Installing Exhaust Manifold
    61
  - Removing the Main Silencer
    62
  - Tighten Screw
    62
  - Guideline
    62
  - Installing the Main Silencer
    63
- 06/Air Filter
  65
- 07/Fuel Tank, Seat, Trim
  68
  - Opening Filler Cap
    68
  - Closing Filler Cap
    68
  - Removing the Seat
    68
  - Mounting the Seat
    68
  - Taking off the Side Cover
    69
  - Mounting the Side Cover
    69
  - Checking the Fuel Pressure
    69
  - Changing the Fuel Filter
    70
- Mount and Tighten Screw Guideline Screw, Fuel Tank, Bottom
  72
  - Screw, Fuel Tank, Bottom M8
    72
- Repeat the Operation on the Opposite Side
  72
- Lift the Rear Fairing
  73
- Mount and Tighten Screws  . Guideline Screw, Main Silencer M8
  73
  - Holder on Fuel Tank
    73
  - Loctite
    73
- 09/Front Wheel
  74
- 10/Rear Wheel
  77
- 11/Wiring Harness, Battery
  83
  - Removing the Battery
    83
  - Installing the Battery
    83
  - Disconnecting the Battery
    83
  - Connecting the Battery
    84
  - Recharging the Battery
    84
  - Checking the Charging Voltage
    85
  - Changing the Main Fuse
    85
  - Changing Fuses of Individual Power Consumers
    86
  - Adjusting the Engine Characteristic
    87
- 13/Brake System
  88
- 14/Light System, Instruments
  98
- 30/Engine
  106
  - Removing the Engine
    106
  - Installing the Engine
    108
- 30/Disassembling the Engine
  112
  - Clamping Engine into Engine Work Stand
    112
  - Draining the Engine Oil
    112
  - Removing Starter Motor
    112
  - Removing Valve Cover
    112
  - Removing the Alternator Cover
    113
  - Removing Spacer
    113
  - Removing Gear Position Sensor
    113
  - Removing Oil Filter
    113
  - Removing Thermostat
    114
  - Setting Engine to Ignition Top Dead Center
    114
  - Removing Water Pump Wheel
    114
  - Removing Clutch Cover
    115
  - Removing Spacer and Spring
    115
  - Removing Spark Plug
    115
  - Removing Timing Chain Tensioner
    116
  - Removing Camshafts
    116
  - Removing Cylinder Head
    116
  - Removing Piston
    116
  - Removing Rotor
    117
  - Removing Timing Chain Rails
    117
  - Removing Timing Chain and Timing Chain Sprocket
    118
  - Removing Crankshaft Position Sensor
    118
  - Removing Clutch Cage
    118
  - Removing Primary Gear
    120
  - Removing Starter Drive
    120
  - Removing Shift Shaft
    120
  - Removing Shift Drum Locating
    120
  - Removing Locking Lever
    121
  - Removing Oil Pumps
    121
  - Removing Left Engine Case
    121
  - Removing Crankshaft and Balancer Shaft
    122
  - Removing Transmission Shafts
    122
- 30/Engine - 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
    126
  - Removing Crankshaft Bearing Inner Ring
    127
  - Removing Balancer Shaft Drive Wheel
    127
  - Changing the Conrod Bearing
    127
  - Checking Crankshaft Run-Out at Bearing Pin
    129
  - Installing Balancer Shaft Drive Wheel
    129
  - Installing Crankshaft Bearing Inner Ring
    129
  - Measuring Axial Clearance of Crankshaft and Balancer Shaft
    130
  - Cylinder - Nikasil Coating
    130
  - Checking/Measuring the Cylinder
    131
  - Checking/Measuring the Piston
    131
  - Checking Piston Ring End Gap
    132
  - Checking Piston/Cylinder Mounting Clearance
    133
  - Checking Oil Pumps for Wear
    133
  - Replacing Autodecompressor
    133
  - Preparing Timing Chain Tensioner for Installation
    134
  - Checking Timing Assembly
    135
  - Removing Rocker Arm
    135
  - Changing Camshaft Bearing
    135
  - Removing Valves
    136
  - Checking Valves
    137
  - Checking Valve Springs
    137
  - Checking Valve Spring Retainer
    137
  - Checking Cylinder Head
    137
  - Installing Valves
    138
  - Installing Rocker Arm
    139
  - Dismantling Antihopping Clutch
    139
  - Checking the Clutch
    140
  - Preassembling Antihopping Clutch
    141
  - Checking Shift Mechanism
    142
  - Preassembling Shift Shaft
    142
  - Disassembling the Main Shaft
    143
  - Dismantling Countershaft
    144
  - Checking the Transmission
    145
  - Assembling the Main Shaft
    147
  - Assembling Countershaft
    148
  - Checking Electric Starter Drive
    149
  - Removing Freewheel
    150
  - Checking Freewheel
    150
  - Installing Freewheel
    151
- 30/Assembling the Engine
  152
  - Installing Transmission Shafts
    152
  - Installing Crankshaft and Balancer Shaft
    153
  - Installing Left Engine Case
    153
  - Installing Oil Pumps
    154
  - Installing Locking Lever
    154
  - Installing Shift Drum Locating
    154
  - Installing Shift Shaft
    155
  - Installing Starter Drive
    155
  - Installing Primary Gear
    155
  - Installing Clutch Cage
    156
  - Installing Crankshaft Position Sensor
    157
  - Installing Timing Chain and Timing Chain Sprocket
    157
  - Installing Timing Chain Rails
    158
  - Installing Rotor
    158
  - Adjusting Crankshaft Position Sensor Distance
    158
  - Setting Engine to Top Dead Center
    159
  - Installing Piston
    159
  - Installing Cylinder Head
    160
  - Installing Camshafts
    161
  - Installing Timing Chain Tensioner
    161
  - Checking Valve Clearance
    162
  - Adjusting Valve Clearance
    162
  - Installing Spark Plug
    163
  - Installing Spacer and Spring
    163
  - Installing Clutch Cover
    163
  - Mounting Water Pump Cover
    164
  - Installing Thermostat
    164
  - Installing the Oil Filter
    164
  - Installing Gear Position Sensor
    165
  - Installing the Spacer
    165
  - Installing Oil Screens
    166
  - Installing Alternator Cover
    166
  - Installing Starter Motor
    167
  - Installing Valve Cover
    167
  - Taking Engine off Universal Mounting Rack
    167
- 32/Clutch
  168
  - Checking/Rectifying the Fluid Level of the Hydraulic Clutch
    168
- 35/Water Pump, Cooling System
  169
  - Draining the Coolant
    169
  - Filling the Cooling System
    169
  - Checking the Antifreeze and Coolant Level
    170
  - Checking the Coolant Level
    171
- 38/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
- 39/Ignition System
  178
- 41/Throttle Valve Body
  180
- Technical Data - Engine
  188
  - Capacity - Engine Oil
    188
  - Capacity - Coolant
    188
- Technical Data - Tolerance, Wear Limits of Engine
  189
- Technical Data - Engine Tightening Torques
  191
- Technical Data - Chassis
  193
  - Lighting Equipment
    194
  - Capacity - Fuel
    194
- Technical Data - Fork
  195
  - 690 Enduro
    195
  - 690 Enduro R
    195
- Technical Data - Shock Absorber
  196
  - 690 Enduro
    196
  - 690 Enduro R
    196
- Technical Data - Chassis Tightening Torques
  198
- Cleaning/Protective Treatment
  200
  - Cleaning the Motorcycle
    200
  - Protective Treatment for Winter Operation
    201
- Storage
  202
  - Putting into Operation after Storage
    202
- Service Schedule
  203
- Wiring Diagram
  204
  - 690 Enduro)
    204
  - 690 Enduro)
    206
  - 690 Enduro)
    208
  - 690 Enduro)
    210
  - 690 Enduro)
    212
  - 690 Enduro)
    214
  - 690 Enduro)
    216
  - 690 Enduro)
    218
  - 690 Enduro)
    220
  - 690 Enduro)
    222
  - 690 Enduro R)
    224
  - 690 Enduro R)
    226
  - 690 Enduro R)
    228
  - 690 Enduro R)
    230
  - 690 Enduro R)
    232
  - 690 Enduro R)
    234
  - 690 Enduro R)
    236
  - 690 Enduro R)
    238
  - 690 Enduro R)
    240
  - 690 Enduro R)
    242
- Substances
  244
- Auxiliary Substances
  246
- Special Tools
  248
- Standards
  260
- Index
  261

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KTM 690 ENDURO AUS/UK 2009 Owner's Manual

KTM 690 ENDURO AUS/UK 2009 Owner's Manual (181 pages)

Brand: KTM | Category: Motorcycle | Size: 2 MB

Table of Contents

Table of Contents
5
Means of Representation
8
Important Notes
9
View of Vehicle
14
- View of Vehicle, Front Left Side
  14
- View of Vehicle, Rear Right
  16
Location of Serial Numbers
18
- Chassis Number
  18
- Type Label
  18
- Key Number
  19
- Engine Number
  19
- Fork Part Number
  20
- Shock Absorber Part Number
  20
Controls
21
- Clutch Lever
  21
- Hand Brake Lever
  21
- Light Switch
  22
- Flasher Switch
  22
- Horn Button
  23
- Emergency off Switch
  23
- Electric Starter Button
  24
- Ignition/Steering Lock
  24
- Combination Instrument
  25
- Combination Instrument - Function Buttons
  25
- Combination Instrument - Tachometer
  26
- Combination Instrument - Control Lamps
  26
- Combination Instrument - Display
  27
- Combination Instrument - Speedometer
  28
- Setting Kilometers or Miles
  28
- Combination Instrument - Time
  29
- Setting the Clock
  29
- Combination Instrument - Display ODO
  30
- Combination Instrument - Setting/Resetting TRIP 1
  30
- Combination Instrument - Setting/Resetting TRIP 2
  31
- Combination Instrument - TRIP F Display
  32
- Combination Instrument - Coolant Temperature Indicator
  32
- Opening Filler Cap
  33
- Closing Filler Cap
  33
- Handrails
  34
- Seat Release
  34
- Passenger Footrests
  35
- Shift Lever
  35
- Foot Brake Pedal
  36
- Side Stand
  37
General Tips and Hints on Putting into Operation
38
- Advice on First Use
  38
- Running in the Engine
  39
- Loading the Vehicle
  40
Riding Instructions
42
- Checks before Putting into Operation
  42
- Starting
  43
- Starting up
  45
- Shifting, Riding
  45
- Braking
  48
- Stopping, Parking
  49
- Refueling
  51
Service Schedule
53
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop
  53
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)
  55
Maintenance Work on Chassis and Engine
57
Checking Rear Sprocket / Engine Sprocket for Wear
74
Checking Chain Wear
75
Adjusting Chain Guide
76
Checking Brake Discs
76
Checking Free Play of Hand Brake Lever
77
Adjusting Free Travel of Handbrake Lever
78
Checking the Front Brake Fluid Level
79
Adding Front Brake Fluid
79
Checking the Front Brake Linings
81
Changing the Front Brake Linings
82
Checking Free Play of Foot Brake Lever
85
Adjusting Basic Position of Foot Brake Pedal
86
Checking Rear Brake Fluid Level
87
Adding Rear Brake Fluid
87
Checking the Rear Brake Linings
89
Changing the Rear Brake Linings
89
Removing the Front Wheel
92
Installing the Front Wheel
94
Removing Rear Wheel
95
Installing the Rear Wheel
96
Checking the Rear Hub Rubber Dampers
97
Checking the Tire Condition
98
Checking Tire Air Pressure
100
Checking Spoke Tension
101
Removing the Seat
102
Mounting the Seat
103
Removing the Battery
103
Installing the Battery
104
Recharging the Battery
105
Changing the Main Fuse
107
Changing the Fuses of Power Consumers
109
Adjusting the Engine Characteristic
111
Removing the Headlight Mask with the Headlight
113
Refitting the Headlight Mask with the Headlight
114
Changing the Headlight Bulb
115
Changing the Parking Light Bulb
116
Changing the Flasher Bulb
117
Checking Headlamp Setting
118
Adjusting the Headlight Range
119
Removing the Air Filter
119
Installing the Air Filter
120
Cooling System
121
Checking the Antifreeze and Coolant Level
122
Checking the Coolant Level
124
Draining the Coolant
126
Filling the Cooling System
127
Adjusting Basic Position of Clutch Lever
129
Checking/Rectifying the Fluid Level of the Hydraulic Clutch
129
Checking Play in Gas Bowden Cable
130
Adjusting the Play in the Gas Bowden Cable
131
Removing the Engine Guard
132
Installing the Engine Guard
132
Checking Engine Oil Level
133
Changing the Engine Oil and Filter, Cleaning the Oil Screens
133
Draining the Engine Oil
134
Removing the Oil Filter
135
- Installing the Oil Filter
  137
- Cleaning the Oil Screens
  137
- Filling up with Engine Oil
  139
- Topping up Engine Oil
  140
Troubleshooting
142
Flashing Code
145
Cleaning
150
- Cleaning Motorcycle
  150
Conserving for Winter Operation
152
- Conservation for Winter Operation
  152
Storage
153
- Putting into Operation after Storage
  154
Technical Data - Engine
155
- Capacity- Engine Oil
  156
- Capacity - Coolant
  156
Technical Data - Engine Tightening Torques
157
Technical Data - Chassis
160
- Lighting Equipment
  161
- Capacity - Fuel
  162
Technical Data - Fork
163
Technical Data - Shock Absorber
164
Technical Data - Chassis Tightening Torques
166
Substances
169
Auxiliary Substances
173
Standards
175
Index
176

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