Ktm 690 Enduro R 2012 Workshop Service Repair Manual – PDF Download

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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

KTM 690 ENDURO R 2012 WORKSHOP SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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• 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

PLEASE NOTE:

⦁ 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