Ktm 690 Enduro R 2012 Workshop Service Repair Manual
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Ktm 690 Enduro R 2012 Workshop Service Repair Manual
LANGUAGE:ENGLISH
PAGES:231
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
- Ktm 690 Enduro R 2012 Workshop Service Repair Manual
- The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer’s Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
- Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet. 3.2 Operating and auxiliary substances Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system.
- Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. 3.3 Spare parts, accessories Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PowerParts for your vehicle can be found on the KTM website.
- International KTM 3.4 Figures The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
TABLE OF CONTENTS:
Ktm 690 Enduro R 2012 Workshop Service Repair Manual
1 MEANS OF REPRESENTATION............................................................. 5 1.1 Symbols used.................................................................. 5 1.2 Formats used.................................................................. 5 2 SAFETY ADVICE....................................................................... 6 2.1 Repair Manual................................................................. 6 2.2 Safety advice................................................................. 6 2.3 Degrees of risk and symbols................................................... 6 2.4 Work rules.................................................................... 6 3 IMPORTANT NOTES..................................................................... 7 3.1 Guarantee, warranty........................................................... 7 3.2 Operating and auxiliary substances............................................ 7 3.3 Spare parts, accessories...................................................... 7 3.4 Figures....................................................................... 7 4 SERIAL NUMBERS...................................................................... 8 4.1 Chassis number................................................................ 8 4.2 Type label.................................................................... 8 4.3 Engine number................................................................. 8 4.4 Key number.................................................................... 8 4.5 Fork part number.............................................................. 8 4.6 Shock absorber part number.................................................... 9 5 MOTORCYCLE.......................................................................... 10 5.1 Raising the motorcycle with the lift stand.................................... 10 5.2 Removing the motorcycle from the lift stand................................... 10 5.3 Raising the motorcycle with the work stand.................................... 10 5.4 Removing the motorcycle from the work stand................................... 11 5.5 Starting...................................................................... 11 5.6 Starting the motorcycle to make checks........................................ 12 6 FORK, TRIPLE CLAMP.................................................................. 13 6.1 Adjusting the compression damping of the fork................................. 13 6.2 Adjusting the rebound damping of the fork..................................... 13 6.3 Bleeding the fork legs........................................................ 13 6.4 Cleaning the dust boots of the fork legs...................................... 14 6.5 Loosening the fork protection................................................. 14 6.6 Positioning the fork protection............................................... 14 6.7 Removing the fork legs........................................................ 15 6.8 Installing the fork legs...................................................... 16 6.9 Servicing the fork............................................................ 17 6.10 Disassembling the fork legs.................................................. 18 6.11 Disassembling the cartridge.................................................. 21 6.12 Disassembling the tap compression............................................ 22 6.13 Checking the fork legs....................................................... 23 6.14 Assembling the tap compression............................................... 24 6.15 Assembling the cartridge..................................................... 25 6.16 Assembling the fork legs..................................................... 27 6.17 Checking the steering head bearing play...................................... 31 6.18 Adjusting the play of the steering head bearing.............................. 31 7 HANDLEBAR, CONTROLS................................................................. 33 7.1 Handlebar position............................................................ 33 7.2 Adjusting handlebar position.................................................. 33 7.3 Checking the routing of the throttle cable.................................... 33 7.4 Checking the play in the throttle cable....................................... 34 7.5 Adjusting the play in the throttle cable...................................... 34 8 FRAME............................................................................... 36 8.1 Removing the engine guard..................................................... 36 8.2 Installing the engine guard................................................... 36 9 SHOCK ABSORBER, SWINGARM............................................................ 37 9.1 Adjusting the high-speed compression damping of the shock absorber............ 37 9.2 Adjusting the low-speed compression damping of the shock absorber............. 37 9.3 Adjusting the rebound damping of the shock absorber........................... 38 9.4 Measuring the unloaded rear wheel sag......................................... 38 9.5 Checking the static sag of the shock absorber................................. 38 9.6 Checking the riding sag of the shock absorber................................. 39 9.7 Adjusting the spring preload of the shock absorber............................ 39 9.8 Adjusting the riding sag...................................................... 40 9.9 Removing the shock absorber................................................... 40 9.10 Installing the shock absorber................................................ 41 9.11 Servicing the shock absorber................................................. 42 9.12 Removing the spring.......................................................... 43 9.13 Dismantling the damper....................................................... 43 9.14 Disassembling the piston rod................................................. 44 9.15 Checking the damper.......................................................... 45 9.16 Removing the heim joint...................................................... 46 9.17 Installing the heim joint.................................................... 47 9.18 Assembling the piston rod.................................................... 48 9.19 Assembling the damper........................................................ 49 9.20 Bleeding and filling the damper.............................................. 51 9.21 Filling the damper with nitrogen............................................. 53 9.22 Installing the spring........................................................ 54 10 EXHAUST............................................................................ 56 10.1 Removing the manifold........................................................ 56 10.2 Installing the manifold...................................................... 56 10.3 Removing the main silencer................................................... 57 10.4 Installing the main silencer................................................. 58 11 AIR FILTER......................................................................... 59 11.1 Removing the air filter...................................................... 59 11.2 Installing the air filter.................................................... 59 11.3 Removing the air filter box.................................................. 59 11.4 Installing the air filter box................................................ 60 12 FUEL TANK, SEAT, TRIM.............................................................. 62 12.1 Opening the filler cap....................................................... 62 12.2 Closing filler cap........................................................... 62 12.3 Removing the seat............................................................ 62 12.4 Mounting the seat............................................................ 63 12.5 Taking off the side cover.................................................... 63 12.6 Mounting the side cover...................................................... 63 12.7 Checking the fuel pressure................................................... 64 12.8 Changing the fuel filter..................................................... 65 12.9 Changing the fuel pump....................................................... 68 13 WHEELS............................................................................. 71 13.1 Checking the tire air pressure............................................... 71 13.2 Checking the tire condition.................................................. 71 13.3 Checking the brake discs..................................................... 72 13.4 Checking the spoke tension................................................... 72 13.5 Checking the rim run-out..................................................... 73 13.6 Front wheel.................................................................. 73 13.6.1 Removing the front wheel............................................... 73 13.6.2 Installing the front wheel............................................. 74 13.6.3 Removing the brake disc of the front brake............................. 74 13.6.4 Installing the brake disc of the front brake........................... 75 13.7 Rear wheel................................................................... 75 13.7.1 Removing rear wheel.................................................... 75 13.7.2 Installing the rear wheel.............................................. 75 13.7.3 Removing the brake disc of the rear brake.............................. 76 13.7.4 Installing the brake disc of the rear brake............................ 77 13.7.5 Checking the chain tension............................................. 77 13.7.6 Adjusting the chain tension............................................ 77 13.7.7 Adjusting chain guide.................................................. 78 13.7.8 Checking the chain, rear sprocket, engine sprocket, and chain guide.... 78 13.7.9 Cleaning the chain..................................................... 80 13.7.10 Checking the rear hub rubber dampers.................................. 80 14 WIRING HARNESS, BATTERY............................................................ 82 14.1 Removing the battery......................................................... 82 14.2 Installing the battery....................................................... 82 14.3 Disconnecting the battery.................................................... 82 14.4 Connecting the battery....................................................... 83 14.5 Recharging the battery....................................................... 83 14.6 Checking the charging voltage................................................ 84 14.7 Changing the main fuse....................................................... 85 14.8 Changing fuses of individual power consumers................................. 85 14.9 Adjusting the engine characteristic.......................................... 86 15 BRAKE SYSTEM....................................................................... 88 15.1 Checking the front brake linings............................................. 88 15.2 Changing the front brake linings............................................. 88 15.3 Checking the free travel of the hand brake lever............................. 90 15.4 Adjusting the free travel of the hand brake lever............................ 90 15.5 Checking the front brake fluid level......................................... 90 15.6 Adding front brake fluid..................................................... 91 15.7 Changing the front brake fluid............................................... 91 15.8 Checking the rear brake linings.............................................. 93 15.9 Changing the rear brake linings.............................................. 93 15.10 Checking the free travel of foot brake lever................................ 94 15.11 Adjusting the basic position of the foot brake lever........................ 95 15.12 Checking rear brake fluid level............................................. 95 15.13 Adding rear brake fluid..................................................... 96 15.14 Changing the rear brake fluid............................................... 96 16 LIGHTING SYSTEM, INSTRUMENTS....................................................... 98 16.1 Combination instrument....................................................... 98 16.1.1 Setting kilometers or miles............................................ 98 16.1.2 Setting the clock...................................................... 98 16.1.3 Setting/resetting display TRIP 1....................................... 98 16.1.4 Setting/resetting display TRIP 2....................................... 98 16.1.5 Setting the wheel circumference........................................ 99 16.2 Checking the headlight setting...............................................100 16.3 Adjusting the headlight range................................................100 16.4 Removing the headlight mask with the headlight...............................100 16.5 Installing the headlight mask with the headlight.............................101 16.6 Changing the parking light bulb..............................................101 16.7 Changing the headlight bulb..................................................102 16.8 Changing the turn signal bulb................................................102 17 ENGINE.............................................................................104 17.1 Removing the engine..........................................................104 17.2 Installing the engine........................................................106 17.3 Engine disassembly...........................................................110 17.3.1 Clamping the engine into the engine assembly stand.....................110 17.3.2 Draining the engine oil................................................110 17.3.3 Removing starter motor.................................................111 17.3.4 Removing valve cover...................................................111 17.3.5 Removing the alternator cover..........................................111 17.3.6 Removing spacer........................................................111 17.3.7 Removing gear position sensor..........................................111 17.3.8 Removing oil filter....................................................112 17.3.9 Removing thermostat....................................................112 17.3.10 Setting engine to ignition top dead center............................112 17.3.11 Removing water pump wheel.............................................113 17.3.12 Removing clutch cover.................................................113 17.3.13 Removing spacer and spring............................................114 17.3.14 Removing spark plug...................................................114 17.3.15 Removing timing chain tensioner.......................................114 17.3.16 Removing camshafts....................................................114 17.3.17 Removing cylinder head................................................115 17.3.18 Removing piston.......................................................115 17.3.19 Removing rotor........................................................115 17.3.20 Removing timing chain rails...........................................116 17.3.21 Removing timing chain and timing chain sprocket.......................116 17.3.22 Removing crankshaft position sensor...................................117 17.3.23 Removing clutch cage..................................................117 17.3.24 Removing primary gear.................................................118 17.3.25 Removing starter drive................................................118 17.3.26 Removing shift shaft..................................................119 17.3.27 Removing shift drum locating..........................................119 17.3.28 Removing locking lever................................................119 17.3.29 Removing oil pumps....................................................119 17.3.30 Removing left engine case.............................................120 17.3.31 Removing crankshaft and balancer shaft................................120 17.3.32 Removing transmission shafts..........................................121 17.4 Work on individual parts.....................................................122 17.4.1 Work on the right section of the engine case...........................122 17.4.2 Work on the left section of the engine case............................123 17.4.3 Work on the clutch cover...............................................125 17.4.4 Removing crankshaft bearing inner ring.................................125 17.4.5 Removing balancer shaft drive wheel....................................125 17.4.6 Changing the connecting rod, conrod bearing, and crank pin.............125 17.4.7 Checking crankshaft run-out at bearing pin.............................127 17.4.8 Installing balancer shaft drive wheel..................................127 17.4.9 Installing crankshaft bearing inner ring...............................128 17.4.10 Measuring axial clearance of crankshaft and balancer shaft............128 17.4.11 Cylinder - Nikasil® coating...........................................129 17.4.12 Checking/measuring the cylinder.......................................129 17.4.13 Checking/measuring the piston.........................................130 17.4.14 Checking piston ring..................................................131 17.4.15 Checking piston/cylinder mounting clearance...........................131 17.4.16 Checking oil pumps for wear...........................................131 17.4.17 Replacing autodecompressor............................................132 17.4.18 Preparing timing chain tensioner for installation.....................132 17.4.19 Checking timing assembly..............................................133 17.4.20 Removing rocker arm...................................................133 17.4.21 Changing camshaft bearing.............................................134 17.4.22 Removing valves.......................................................135 17.4.23 Checking valves.......................................................135 17.4.24 Checking valve springs................................................136 17.4.25 Checking valve spring retainer........................................136 17.4.26 Checking cylinder head................................................136 17.4.27 Installing valves.....................................................137 17.4.28 Installing rocker arm.................................................137 17.4.29 Disassembling the antihopping clutch..................................138 17.4.30 Checking the clutch...................................................138 17.4.31 Preassembling the antihopping clutch..................................140 17.4.32 Checking shift mechanism..............................................141 17.4.33 Preassembling shift shaft.............................................141 17.4.34 Disassembling the main shaft..........................................142 17.4.35 Dismantling countershaft..............................................142 17.4.36 Checking the transmission.............................................143 17.4.37 Assembling the main shaft.............................................144 17.4.38 Assembling countershaft...............................................145 17.4.39 Checking the starter drive............................................146 17.4.40 Removing freewheel....................................................146 17.4.41 Checking freewheel....................................................147 17.4.42 Installing freewheel..................................................147 17.5 Engine assembly..............................................................148 17.5.1 Installing transmission shafts.........................................148 17.5.2 Installing crankshaft and balancer shaft...............................149 17.5.3 Installing left engine case............................................150 17.5.4 Installing oil pumps...................................................150 17.5.5 Installing locking lever...............................................151 17.5.6 Installing shift drum locating.........................................151 17.5.7 Installing shift shaft.................................................151 17.5.8 Installing starter drive...............................................151 17.5.9 Installing primary gear................................................152 17.5.10 clutch cage, installing...............................................152 17.5.11 Installing crankshaft position sensor.................................153 17.5.12 Installing timing chain and timing chain sprocket.....................154 17.5.13 Installing timing chain rails.........................................154 17.5.14 Installing rotor......................................................154 17.5.15 Adjusting crankshaft position sensor distance.........................155 17.5.16 Setting engine to top dead center.....................................155 17.5.17 Installing piston.....................................................155 17.5.18 Installing cylinder head..............................................157 17.5.19 Installing camshafts..................................................157 17.5.20 Installing timing chain tensioner.....................................158 17.5.21 Checking valve clearance..............................................158 17.5.22 Adjusting valve clearance.............................................159 17.5.23 Installing spark plug.................................................160 17.5.24 Installing spacer and spring..........................................160 17.5.25 Installing clutch cover...............................................160 17.5.26 Mounting water pump cover.............................................160 17.5.27 Installing thermostat.................................................161 17.5.28 Installing the oil filter.............................................161 17.5.29 Installing gear position sensor.......................................161 17.5.30 Installing the spacer.................................................162 17.5.31 Installing oil screens................................................162 17.5.32 Installing alternator cover...........................................163 17.5.33 Installing the starter motor..........................................163 17.5.34 Installing valve cover................................................164 17.5.35 Removing the engine from the engine assembly stand....................164 18 CLUTCH.............................................................................165 18.1 Checking/rectifying the fluid level of the hydraulic clutch..................165 18.2 Changing the hydraulic clutch fluid..........................................165 19 WATER PUMP, COOLING SYSTEM.........................................................166 19.1 Draining the coolant.........................................................166 19.2 Filling/bleeding the cooling system..........................................166 19.3 Checking the antifreeze and coolant level....................................167 19.4 Checking the coolant level...................................................168 20 LUBRICATION SYSTEM.................................................................169 20.1 Oil circuit..................................................................169 20.2 Checking the engine oil level................................................169 20.3 Checking the engine oil pressure.............................................170 20.4 Changing the engine oil and filter, cleaning the oil screens.................171 20.5 Draining the engine oil......................................................171 20.6 Removing the oil filter......................................................172 20.7 Installing the oil filter....................................................172 20.8 Cleaning the oil screens.....................................................173 20.9 Filling up with engine oil...................................................174 20.10 Adding engine oil...........................................................174 21 IGNITION SYSTEM....................................................................175 21.1 Alternator - checking the stator winding.....................................175 21.2 Checking the spark plug connector............................................175 21.3 Ignition coil - checking the secondary winding...............................176 22 TECHNICAL DATA.....................................................................177 22.1 Engine.......................................................................177 22.2 Engine tolerance, wear limits................................................177 22.3 Engine tightening torques....................................................179 22.4 Capacities...................................................................180 22.4.1 Engine oil.............................................................180 22.4.2 Coolant................................................................180 22.4.3 Fuel...................................................................180 22.5 Chassis......................................................................180 22.6 Electrical system............................................................181 22.7 Tires........................................................................181 22.8 Fork.........................................................................182 22.9 Shock absorber...............................................................182 22.10 Chassis tightening torques..................................................183 23 CLEANING/PROTECTIVE TREATMENT......................................................185 23.1 Cleaning the motorcycle......................................................185 23.2 Checks and maintenance steps for winter operation............................186 24 STORAGE............................................................................187 24.1 Storage......................................................................187 24.2 Preparing for use after storage..............................................187 25 SERVICE SCHEDULE...................................................................188 25.1 Service schedule.............................................................188 26 WIRING DIAGRAM.....................................................................190 26.1 Page 01 of 10................................................................190 26.2 Page 02 of 10................................................................192 26.3 Page 03 of 10................................................................194 26.4 Page 04 of 10................................................................196 26.5 Page 05 of 10................................................................198 26.6 Page 06 of 10................................................................200 26.7 Page 07 of 10................................................................202 26.8 Page 08 of 10................................................................204 26.9 Page 09 of 10................................................................206 26.10 Page 10 of 10...............................................................208 27 SUBSTANCES.........................................................................210 28 AUXILIARY SUBSTANCES...............................................................212 29 SPECIAL TOOLS......................................................................214 30 STANDARDS..........................................................................227 INDEX.................................................................................228 A.................................................................................228 B.................................................................................228 C.................................................................................228 D.................................................................................229 E.................................................................................229 F.................................................................................229 H.................................................................................230 I.................................................................................230 K.................................................................................230 M.................................................................................230 O.................................................................................230 P.................................................................................230 R.................................................................................230 S.................................................................................230 T.................................................................................231 W.................................................................................231
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual