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17 ENGINE 113

17.3.4 Removing valve cover

300003-10

– Remove screws 1. Take off the valve cover with the valve cover seal.

17.3.5 Removing the alternator cover

300004-10

– Remove screws 1. Take off the alternator cover.

– Remove dowels.

17.3.6 Removing spacer

302124-10

– Remove the spacer 1 of the countershaft.

17.3.7 Removing gear position sensor

302126-10

– Remove screws. Remove the gear position sensor 1.

300007-10

– Remove O-ring 2.

– Remove contact pin 3 and the contact springs 4.

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Repair Manual8
- Degrees of Risk and Symbols8
- Work Rules8
3 Important Notes9
- Guarantee, Warranty9
- Operating and Auxiliary Substances9
- Spare Parts, Accessories9
- Figures9
4 Serial Numbers10
- Chassis Number10
- Type Label10
- Engine Number10
- Key Number10
- Fork Part Number10
- Shock Absorber Part Number11
5 Motorcycle12
- Raising the Motorcycle with the Lift Stand12
- Removing the Motorcycle from the Lift Stand12
- Raising the Motorcycle with the Work Stand12
- Removing the Motorcycle from the Work Stand13
- Starting13
- Starting the Motorcycle to Make Checks14
6 Fork, Triple Clamp15
- Adjusting the Compression Damping of the Fork15
- Adjusting the Rebound Damping of the Fork15
- Bleeding the Fork Legs15
- Cleaning the Dust Boots of the Fork Legs16
- Loosening the Fork Protection16
- Positioning the Fork Protection16
- Removing Fork Legs17
- Installing the Fork Legs18
- Servicing the Fork19
- Disassembling the Fork Legs20
- Disassembling the Cartridge23
- Disassembling the Tap Compression24
- Checking the Fork Legs25
- Assembling the Tap Compression26
- Assembling the Cartridge27
- Assembling the Fork Legs29
- Checking the Steering Head Bearing Play33
- Adjusting the Play of the Steering Head Bearing33
7 Handlebar, Controls35
- Handlebar Position35
- Adjusting Handlebar Position35
- Checking the Routing of the Throttle Cable35
- Checking the Play in the Throttle Cable36
- Adjusting the Play in the Throttle Cable36
8 Frame38
- Removing the Engine Guard38
- Installing the Engine Guard38
9 Shock Absorber, Swingarm39
- Adjusting the High-Speed Compression Damping of the Shock Absorber39
- Adjusting the Low-Speed Compression Damping of the Shock Absorber39
- Adjusting the Rebound Damping of the Shock Absorber40
- Measuring the Unloaded Rear Wheel Sag40
- Checking the Static Sag of the Shock Absorber40
- Checking the Riding Sag of the Shock Absorber41
- Adjusting the Spring Preload of the Shock Absorber41
- Adjusting the Riding Sag42
- Removing the Shock Absorber42
- Installing the Shock Absorber43
- Servicing the Shock Absorber45
- Removing the Spring45
- Dismantling the Damper46
- Disassembling the Piston Rod47
- Checking the Damper48
- Removing the Heim Joint49
- Installing the Heim Joint50
- Assembling the Piston Rod51
- Assembling the Damper52
- Bleeding and Filling the Damper54
- Filling the Damper with Nitrogen56
- Installing the Spring57
10 Exhaust59
- Removing the Manifold59
- Installing the Manifold60
- Removing the Main Silencer61
- Installing the Main Silencer61
- Guideline61
- Position the Screw Clamp62
- Tighten Screw Guideline Screw, Main Silencer Clamp62
- Mount and Tighten Screws Guideline Screw, Exhaust Heat Shield62
11 Air Filter63
- Removing the Air Filter63
- Installing the Air Filter63
- Removing the Air Filter Box63
- Finishing Work63
- Installing the Air Filter Box64
- Mount the Side Cover65
- Mount the Seat65
12 Fuel Tank, Seat, Trim66
- Opening the Filler Cap66
- Closing Filler Cap66
- Removing the Seat66
- Mounting the Seat67
- Taking off the Side Cover67
- Mounting the Side Cover67
- Checking the Fuel Pressure67
- Changing the Fuel Filter68
- Changing the Fuel Pump71
13 Wheels75
- Checking the Tire Air Pressure75
- Checking the Tire Condition75
- Checking the Brake Discs76
- Checking the Spoke Tension76
- Checking the Rim Run-Out77
- Front Wheel77
- Removing the Front Wheel77
- Installing the Front Wheel78
- Removing the Brake Disc of the Front Brake78
- Installing the Brake Disc of the Front Brake79
- Rear Wheel79
- Removing Rear Wheel79
- Installing the Rear Wheel79
- Nm Loctite79
- Removing the Brake Disc of the Rear Brake80
- Installing the Brake Disc of the Rear Brake81
- Checking the Chain Tension81
- Adjusting the Chain Tension81
- Adjusting Chain Guide82
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide82
- Cleaning the Chain84
- Checking the Rear Hub Rubber Dampers84
14 Wiring Harness, Battery86
- Removing the Battery86
- Installing the Battery86
- Disconnecting the Battery86
- Connecting the Battery87
- Recharging the Battery87
- Checking the Charging Voltage88
- Changing the Main Fuse89
- Changing Fuses of Individual Power Consumers89
- Adjusting the Engine Characteristic90
15 Brake System92
- Checking the Front Brake Linings92
- Changing the Front Brake Linings92
- Checking the Free Travel of the Hand Brake Lever94
- Adjusting the Free Travel of the Hand Brake Lever94
- Checking the Front Brake Fluid Level94
- Adding Front Brake Fluid95
- Changing the Front Brake Fluid95
- Checking the Rear Brake Linings96
- Changing the Rear Brake Linings97
- Checking the Free Travel of Foot Brake Lever98
- Adjusting the Basic Position of the Foot Brake Lever98
- Checking Rear Brake Fluid Level99
- Adding Rear Brake Fluid99
- Changing the Rear Brake Fluid100
16 Lighting System, Instruments102
- Combination Instrument102
- Setting Kilometers or Miles102
- Setting the Clock102
- Setting/Resetting Display TRIP 1102
- Setting/Resetting Display TRIP 2102
- Setting the Wheel Circumference103
- Checking the Headlight Setting104
- Adjusting the Headlight Range104
- Removing the Headlight Mask with the Headlight104
- Installing the Headlight Mask with the Headlight105
- Changing the Parking Light Bulb105
- Changing the Headlight Bulb106
- Changing the Turn Signal Bulb106
17 Engine108
- Removing the Engine108
- Installing the Engine110
- Engine Disassembly114
- Clamping the Engine into the Engine Assembly Stand114
- Draining the Engine Oil114
- Removing Starter Motor114
- Removing Valve Cover115
- Removing the Alternator Cover115
- Removing Spacer115
- Removing Gear Position Sensor115
- Removing Oil Filter116
- Removing Thermostat116
- Setting Engine to Ignition Top Dead Center116
- Removing Water Pump Wheel117
- Removing Clutch Cover117
- Removing Spacer and Spring117
- Removing Spark Plug118
- Removing Timing Chain Tensioner118
- Removing Camshafts118
- Removing Cylinder Head118
- Removing Piston119
- Removing Rotor119
- Removing Timing Chain Rails120
- Removing Timing Chain and Timing Chain Sprocket120
- Removing Crankshaft Position Sensor120
- Removing Clutch Cage121
- Removing Primary Gear122
- Removing Starter Drive122
- Removing Shift Shaft122
- Removing Shift Drum Locating122
- Removing Locking Lever123
- Removing Oil Pumps123
- Removing Left Engine Case123
- Removing Crankshaft and Balancer Shaft124
- Removing Transmission Shafts124
- Work on Individual Parts125
- Work on the Right Section of the Engine Case125
- Work on the Left Section of the Engine Case127
- Work on the Clutch Cover128
- Removing Crankshaft Bearing Inner Ring129
- Removing Balancer Shaft Drive Wheel129
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin129
- Checking Crankshaft Run-Out at Bearing Pin131
- Installing Balancer Shaft Drive Wheel131
- Installing Crankshaft Bearing Inner Ring131
- Measuring Axial Clearance of Crankshaft and Balancer Shaft132
- Cylinder - Nikasil ® Coating132
- Checking/Measuring the Cylinder133
- Checking/Measuring the Piston133
- Checking Piston Ring End Gap134
- Checking Piston/Cylinder Mounting Clearance134
- Checking Oil Pumps for Wear135
- Replacing Autodecompressor135
- Preparing Timing Chain Tensioner for Installation136
- Checking Timing Assembly136
- Removing Rocker Arm137
- Changing Camshaft Bearing137
- Removing Valves138
- Checking Valves138
- Checking Valve Springs139
- Checking Valve Spring Retainer139
- Checking Cylinder Head139
- Installing Valves140
- Installing Rocker Arm141
- Disassembling the Antihopping Clutch141
  - Checking the Clutch141
  - Preassembling the Antihopping Clutch143
  - Checking Shift Mechanism144
  - Preassembling Shift Shaft144
  - Disassembling the Main Shaft145
  - Dismantling Countershaft145
  - Checking the Transmission146
  - Assembling the Main Shaft147
  - Assembling Countershaft148
  - Checking the Starter Drive149
  - Removing Freewheel149
  - Checking Freewheel150
  - Installing Freewheel150
  - Engine Assembly151
  - Installing Transmission Shafts151
  - Installing Crankshaft and Balancer Shaft152
  - Installing Left Engine Case153
  - Installing Oil Pumps153
  - Installing Locking Lever154
  - Installing Shift Drum Locating154
  - Installing Shift Shaft154
  - Installing Starter Drive154
  - Installing Primary Gear155
  - Installing Clutch Cage155
  - Installing Crankshaft Position Sensor156
  - Installing Timing Chain and Timing Chain Sprocket157
  - Installing Timing Chain Rails157
  - Installing Rotor157
  - Adjusting Crankshaft Position Sensor Distance158
  - Setting Engine to Top Dead Center158
  - Installing Piston158
  - Installing Cylinder Head160
  - Installing Camshafts160
  - Installing Timing Chain Tensioner161
  - Checking Valve Clearance161
  - Adjusting Valve Clearance162
  - Installing Spark Plug163
  - Installing Spacer and Spring163
  - Installing Clutch Cover163
  - Mounting Water Pump Cover163
  - Installing Thermostat164
  - Installing the Oil Filter164
  - Installing Gear Position Sensor164
  - Installing the Spacer165
  - Installing Oil Screens165
  - Installing Alternator Cover166
  - Installing Starter Motor166
  - Installing Valve Cover167
  - Removing the Engine from the Engine Assembly Stand167
18 Clutch168
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch168
- Changing the Hydraulic Clutch Fluid168
19 Water Pump, Cooling System169
- Draining the Coolant169
- Filling/Bleeding the Cooling System169
- Checking the Antifreeze and Coolant Level170
- Checking the Coolant Level171
20 Lubrication System172
- Lubrication System172
- Oil Circuit172
- Checking the Engine Oil Level172
- Checking the Engine Oil Pressure173
- Changing the Engine Oil and Filter, Cleaning the Oil Screens174
- Draining the Engine Oil174
- Removing the Oil Filter175
- Installing the Oil Filter175
- Cleaning the Oil Screens176
- Filling up with Engine Oil177
- Adding Engine Oil177
21 Ignition System178
- Alternator - Checking the Stator Winding178
- Checking the Spark Plug Connector178
- Ignition Coil - Checking the Secondary Winding179
22 Technical Data180
- Engine180
- Engine Tolerance, Wear Limits180
- Engine Tightening Torques182
- Capacities183
- Engine Oil183
- Coolant183
- Fuel183
- Chassis183
- Electrical System184
- Tires184
- Fork185
- Shock Absorber185
- Chassis Tightening Torques186
23 Cleaning/Protective Treatment188
- Cleaning/Protective Treatment188
- Cleaning the Motorcycle188
- Checks and Maintenance Steps for Winter Operation189
24 Storage190
- Preparing for Use after Storage190
25 Service Schedule191
26 Wiring Diagram194
- 192194
- 194196
- 196198
- 198200
- 200202
- 202204
- 204206
- 206208
- 208210
- 210212
- Substances214
27 Substances216
- Auxiliary Substances216
28 Auxiliary Substances218
- Special Tools218
30 Standards230
- Index231

Brand	KTM
Model	690 Enduro R EU
Category	Motorcycle
Language	English

KTM 690 Enduro R EU Repair Manual

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