Name: KTM 690 Enduro R EU
Brand: KTM
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17 ENGINE 165

17.5.34 Installing valve cover

300003-10

– Put the valve cover in place with the seal. Mount and tighten screws 1.

Guideline

Screw, valve cover M6 10 Nm (7.4 lbf ft)

17.5.35 Removing the engine from the engine assembly stand

300144-11

– Remove the screw 1 or the nut 2.

– Remove the engine from the engine assembly stand.

Info

Have an assistant help you or use a crane.

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

KTM 690 Enduro R EU Repair Manual

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Brand	KTM
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