KTM 690 Enduro - Service Manual / Repair Manual - Wiring Diagram

KTM 690 ENDURO - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual and Wiring Diagram to motorcycles KTM 690 Enduro.

 
CONTENTS:

MEANS OF REPRESENTATION
IMPORTANT NOTES
LOCATION OF SERIAL NUMBERS
- Chassis number/type label (690 Enduro, 690 Enduro R EU, 690 Enduro R AUS/UK)
- Chassis number/type label (690 Enduro R USA)
- Key number
- Engine number
- Fork part number
- Shock absorber part number
MOTORCYCLE
- Raising the motorcycle with the lift stand
- Removing the motorcycle from the lift stand
- Raising the motorcycle with the work stand
- Removing the motorcycle from the work stand
- Starting
- Starting the motorcycle to make checks
01/FORK, TRIPLE CLAMP
- Adjusting the compression damping of the fork
- Adjusting the rebound damping of the fork
- Bleeding the fork legs
- Cleaning the dust boots of the fork legs
- Loosening the fork protection
- Positioning the fork protection
- Removing fork legs
- Installing the fork legs
- Servicing the fork
- Disassembling the fork legs
- Disassembling the cartridge
- Disassembling the tap compression
- Checking the fork legs (690 Enduro)
- Checking the fork legs (690 Enduro R)
- Assembling the tap compression
- Assembling the cartridge
- Assembling the fork legs (690 Enduro)
- Assembling the fork legs (690 Enduro R)
- Checking the steering head bearing play
- Adjusting the play of the steering head bearing
02/HANDLEBAR, INSTRUMENTS
- Handlebar position
- Adjusting handlebar position
- Checking the play in the throttle cable
- Adjusting the play in the throttle cable
03/FRAME
- Removing the engine guard
- Installing the engine guard
04/SHOCK ABSORBER, SWINGARM
- Adjusting the high-speed compression damping of the shock absorber
- Adjusting the low-speed compression damping of the shock absorber
- Adjusting the rebound damping of the shock absorber
- Measuring the unloaded rear wheel sag
- Checking the static sag of the shock absorber
- Checking the riding sag of the shock absorber
- Adjusting the spring preload of the shock absorber
- Adjusting the riding sag
- Removing the shock absorber
- Installing the shock absorber
- Servicing the shock absorber
- Removing the spring
- Dismantling the damper
- Disassembling the piston rod
- Checking the damper
- Removing the heim joint
- Installing the heim joint
- Assembling the piston rod
- Assembling the damper
- Bleeding and filling the damper
- Filling the damper with nitrogen
- Installing the spring
05/EXHAUST
- Removing the exhaust manifold
- Installing exhaust manifold
- Removing the main silencer
- Installing the main silencer
06/AIR FILTER
- Removing the air filter
- Installing the air filter
- Removing the air filter box
- Installing the air filter box
07/FUEL TANK, SEAT, TRIM
- Opening filler cap
- Closing filler cap
- Removing the seat
- Mounting the seat
- Taking off the side cover
- Mounting the side cover
- Checking the fuel pressure
- Changing the fuel filter
09/FRONT WHEEL
- Removing the front wheel
- Installing the front wheel
- Checking the tire air pressure
- Checking the tire condition
- Checking the brake discs
10/REAR WHEEL
- Removing rear wheel
- Installing the rear wheel
- Checking the chain tension
- Adjusting the chain tension
- Adjusting chain guide
- Checking the chain, rear sprocket and engine sprocket
- Cleaning the chain
- Checking the rear hub rubber dampers
- Checking the spoke tension

- Checking the rim run-out
11/WIRING HARNESS, BATTERY
- Removing the battery
- Installing the battery
- Disconnecting the battery
- Connecting the battery
- Recharging the battery
- Checking the charging voltage
- Changing the main fuse
- Changing fuses of individual power consumers
- Adjusting the engine characteristic
13/BRAKE SYSTEM
- Checking the front brake linings
- Changing the front brake linings
- Checking the free travel of the hand brake lever
- Adjusting the free travel of the hand brake lever
- Checking the front brake fluid level
- Adding front brake fluid
- Changing the front brake fluid
- Checking the rear brake linings
- Changing rear brake linings
- Checking the free travel of foot brake lever
- Adjusting the basic position of the foot brake lever
- Checking rear brake fluid level
- Adding rear brake fluid
- Changing the rear brake fluid
14/LIGHT SYSTEM, INSTRUMENTS
- Setting kilometers or miles
- Setting the clock
- Combination instrument - setting/resetting TRIP 1
- Combination instrument - setting/resetting TRIP 2
- Combination instrument - setting the wheel circumference (690 Enduro)
- Checking the headlight setting
- Adjusting the headlight range
- Removing the headlight mask with the headlight
- Installing the headlight mask with the headlight
- Changing the parking light bulb
- Changing the headlight bulb
- Changing the turn signal bulb
30/ENGINE
- Removing the engine
- Installing the engine
30/DISASSEMBLING THE ENGINE
- Clamping engine into engine work stand
- Draining the engine oil
- Removing starter motor
- Removing valve cover
- Removing the alternator cover
- Removing spacer
- Removing gear position sensor
- Removing oil filter
- Removing thermostat
- Setting engine to ignition top dead center
- Removing water pump wheel
- Removing clutch cover
- Removing spacer and spring
- Removing spark plug
- Removing timing chain tensioner
- Removing camshafts
- Removing cylinder head
- Removing piston
- Removing rotor
- Removing timing chain rails
- Removing timing chain and timing chain sprocket
- Removing crankshaft position sensor
- Removing clutch cage
- Removing primary gear
- Removing starter drive
- Removing shift shaft
- Removing shift drum locating
- Removing locking lever
- Removing oil pumps
- Removing left engine case
- Removing crankshaft and balancer shaft
- Removing transmission shafts
30/ENGINE - WORK ON INDIVIDUAL PARTS
- Work on the right section of the engine case
- Work on the left section of the engine case
- Work on the clutch cover
- Removing crankshaft bearing inner ring
- Removing balancer shaft drive wheel
- Changing the conrod bearing
- Checking crankshaft run-out at bearing pin
- Installing balancer shaft drive wheel
- Installing crankshaft bearing inner ring
- Measuring axial clearance of crankshaft and balancer shaft
- Cylinder - Nikasil® coating
- Checking/measuring the cylinder
- Checking/measuring the piston
- Checking piston ring
- Checking piston/cylinder mounting clearance
- Checking oil pumps for wear
- Replacing autodecompressor
- Preparing timing chain tensioner for installation
- Checking timing assembly
- Removing rocker arm
- Changing camshaft bearing
- Removing valves
- Checking valves
- Checking valve springs
- Checking valve spring retainer
- Checking cylinder head
- Installing valves
- Installing rocker arm
- Dismantling antihopping clutch
- Checking the clutch
- Preassembling antihopping clutch
- Checking shift mechanism
- Preassembling shift shaft
- Disassembling the main shaft
- Dismantling countershaft
- Checking the transmission
- Assembling the main shaft
- Assembling countershaft
- Checking electric starter drive
- Removing freewheel
- Checking freewheel
- Installing freewheel
30/ASSEMBLING THE ENGINE
- Installing transmission shafts
- Installing crankshaft and balancer shaft
- Installing left engine case
- Installing oil pumps
- Installing locking lever
- Installing shift drum locating
- Installing shift shaft
- Installing starter drive
- Installing primary gear
- Installing clutch cage
- Installing crankshaft position sensor
- Installing timing chain and timing chain sprocket
- Installing timing chain rails
- Installing rotor
- Adjusting crankshaft position sensor distance
- Setting engine to top dead center
- Installing piston
- Installing cylinder head
- Installing camshafts
- Installing timing chain tensioner
- Checking valve clearance
- Adjusting valve clearance
- Installing spark plug
- Installing spacer and spring
- Installing clutch cover
- Mounting water pump cover
- Installing thermostat
- Installing the oil filter
- Installing gear position sensor
- Installing the spacer
- Installing oil screens
- Installing alternator cover
- Installing starter motor
- Installing valve cover
- Taking engine off universal mounting rack
32/CLUTCH
- Checking/rectifying the fluid level of the hydraulic clutch
35/WATER PUMP, COOLING SYSTEM
- Draining the coolant
- Filling the cooling system
- Checking the antifreeze and coolant level
- Checking the coolant level
38/LUBRICATION SYSTEM
- Oil circuit
- Checking the engine oil level
- Checking the engine oil pressure
- Changing the engine oil and filter, cleaning the oil screens
- Draining the engine oil
- Removing the oil filter
- Installing the oil filter
- Cleaning the oil screens
- Filling up with engine oil
- Adding engine oil
39/IGNITION SYSTEM
- Alternator - checking the stator winding
- Checking the spark plug connector
- Ignition coil - checking the secondary winding
41/THROTTLE VALVE BODY
- Checking the basic setting of the motor drive
- Adjusting the basic setting of the motor drive
- Flashing the EFI control unit and/or the EPT control unit
- Requesting the enabling code
- Coding the EFI control unit and/or EPT control unit
TECHNICAL DATA - ENGINE
- Capacity - engine oil
- Capacity - coolant
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
TECHNICAL DATA - CHASSIS
- Lighting equipment
- Capacity - fuel
TECHNICAL DATA - FORK
- 690 Enduro
- 690 Enduro R
TECHNICAL DATA - SHOCK ABSORBER
- 690 Enduro
- 690 Enduro R
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
CLEANING/PROTECTIVE TREATMENT
- Cleaning the motorcycle
- Protective treatment for winter operation
STORAGE
- Storage
- Putting into operation after storage
SERVICE SCHEDULE
- Service schedule
WIRING DIAGRAM
- Page 1 of 10 (690 Enduro)
- Page 2 of 10 (690 Enduro)
- Page 3 of 10 (690 Enduro)
- Page 4 of 10 (690 Enduro)
- Page 5 of 10 (690 Enduro)
- Page 6 of 10 (690 Enduro)
- Page 7 of 10 (690 Enduro)
- Page 8 of 10 (690 Enduro)
- Page 9 of 10 (690 Enduro)
- Page 10 of 10 (690 Enduro)
- Page 1 of 10 (690 Enduro R)
- Page 2 of 10 (690 Enduro R)
- Page 3 of 10 (690 Enduro R)
- Page 4 of 10 (690 Enduro R)
- Page 5 of 10 (690 Enduro R)
- Page 6 of 10 (690 Enduro R)
- Page 7 of 10 (690 Enduro R)
- Page 8 of 10 (690 Enduro R)
- Page 9 of 10 (690 Enduro R)
- Page 10 of 10 (690 Enduro R)
SUBSTANCES
AUXILIARY SUBSTANCES
SPECIAL TOOLS
STANDARDS
INDEX