KTM 690 Enduro R 2009 Repair manual
REPAIR MANUAL 2009
690 Enduro EU
690 Enduro AUS/UK
690 Enduro R EU
690 Enduro R AUS/UK
690 Enduro R USA
Article no. 3206076en
INTRODUCTION 1
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
Only use ORIGINAL KTM SPARE PARTS.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.
© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number/type label (690 Enduro,
690 Enduro R EU, 690 Enduro R AUS/UK) ....................... 7
Chassis number/type label (690 Enduro R USA) ................. 7
Key number .................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 8
Shock absorber part number............................................. 8
MOTORCYCLE..................................................................... 9
Raising the motorcycle with the lift stand .......................... 9
Removing the motorcycle from the lift stand ...................... 9
Raising the motorcycle with the work stand........................ 9
Removing the motorcycle from the work stand.................. 10
Starting ........................................................................ 10
Starting the motorcycle to make checks........................... 11
01/FORK, TRIPLE CLAMP.................................................. 12
Adjusting the compression damping of the fork ................ 12
Adjusting the rebound damping of the fork....................... 12
Bleeding the fork legs .................................................... 13
Cleaning the dust boots of the fork legs ........................... 13
Loosening the fork protection.......................................... 14
Positioning the fork protection ........................................ 14
Removing fork legs ........................................................ 15
Installing the fork legs ................................................... 16
Servicing the fork .......................................................... 17
Disassembling the fork legs ............................................ 18
Disassembling the cartridge............................................ 20
Disassembling the tap compression................................. 22
Checking the fork legs (690 Enduro) ............................... 23
Checking the fork legs (690 Enduro R) ............................ 24
Assembling the tap compression ..................................... 25
Assembling the cartridge................................................ 26
Assembling the fork legs (690 Enduro) ............................ 27
Assembling the fork legs (690 Enduro R)......................... 31
Checking the steering head bearing play .......................... 35
Adjusting the play of the steering head bearing ................ 35
02/HANDLEBAR, INSTRUMENTS....................................... 37
Handlebar position ........................................................ 37
Adjusting handlebar position .......................................... 37
Checking the play in the throttle cable............................. 37
Adjusting the play in the throttle cable ............................ 38
03/FRAME........................................................................ 39
Removing the engine guard ............................................ 39
Installing the engine guard ............................................. 39
04/SHOCK ABSORBER, SWINGARM................................... 40
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 40
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 40
Adjusting the rebound damping of the shock absorber....... 41
Measuring the unloaded rear wheel sag............................ 42
Checking the static sag of the shock absorber .................. 42
Checking the riding sag of the shock absorber .................. 42
Adjusting the spring preload of the shock absorber ........... 43
Adjusting the riding sag ................................................. 43
Removing the shock absorber ......................................... 44
Installing the shock absorber .......................................... 45
Servicing the shock absorber .......................................... 46
Removing the spring ...................................................... 46
Dismantling the damper ................................................. 47
Disassembling the piston rod .......................................... 48
Checking the damper ..................................................... 49
Removing the heim joint ................................................ 50
Installing the heim joint ................................................. 51
Assembling the piston rod .............................................. 52
Assembling the damper.................................................. 53
Bleeding and filling the damper ...................................... 55
Filling the damper with nitrogen ..................................... 57
Installing the spring....................................................... 58
05/EXHAUST .................................................................... 59
Removing the exhaust manifold ...................................... 59
Installing exhaust manifold............................................. 59
Removing the main silencer............................................ 60
Installing the main silencer ............................................ 61
06/AIR FILTER.................................................................. 63
Removing the air filter ................................................... 63
Installing the air filter .................................................... 63
Removing the air filter box ............................................. 63
Installing the air filter box .............................................. 64
07/FUEL TANK, SEAT, TRIM.............................................. 66
Opening filler cap.......................................................... 66
Closing filler cap ........................................................... 66
Removing the seat ......................................................... 66
Mounting the seat ......................................................... 66
Taking off the side cover ................................................ 67
Mounting the side cover ................................................. 67
Checking the fuel pressure ............................................. 67
Changing the fuel filter .................................................. 68
09/FRONT WHEEL ............................................................ 72
Removing the front wheel............................................... 72
Installing the front wheel................................................ 72
Checking the tire air pressure ......................................... 73
Checking the tire condition............................................. 73
Checking the brake discs................................................ 74
10/REAR WHEEL .............................................................. 75
Removing rear wheel...................................................... 75
Installing the rear wheel................................................. 75
Checking the chain tension ............................................ 76
Adjusting the chain tension ............................................ 76
Adjusting chain guide .................................................... 77
Checking the chain, rear sprocket and engine sprocket...... 77
Cleaning the chain......................................................... 78
Checking the rear hub rubber dampers ............................ 79
Checking the spoke tension ............................................ 79
Checking the rim run-out................................................ 80
11/WIRING HARNESS, BATTERY ....................................... 81
Removing the battery ..................................................... 81
Installing the battery...................................................... 81
Disconnecting the battery............................................... 81
Connecting the battery ................................................... 82
Recharging the battery ................................................... 82
Checking the charging voltage ........................................ 83
Changing the main fuse ................................................. 83
Changing fuses of individual power consumers ................. 84
Adjusting the engine characteristic.................................. 85
13/BRAKE SYSTEM........................................................... 86
Checking the front brake linings...................................... 86
Changing the front brake linings ..................................... 86
Checking the free travel of the hand brake lever ............... 88
Adjusting the free travel of the hand brake lever ............... 88
Checking the front brake fluid level ................................. 88
CONTENTS 3
Adding front brake fluid ................................................. 89
Changing the front brake fluid ........................................ 89
Checking the rear brake linings ....................................... 90
Changing rear brake linings ............................................ 91
Checking the free travel of foot brake lever....................... 92
Adjusting the basic position of the foot brake lever ........... 92
Checking rear brake fluid level........................................ 93
Adding rear brake fluid .................................................. 93
Changing the rear brake fluid.......................................... 94
14/LIGHT SYSTEM, INSTRUMENTS ................................... 96
Setting kilometers or miles ............................................. 96
Setting the clock ........................................................... 96
Combination instrument - setting/resetting TRIP 1............ 97
Combination instrument - setting/resetting TRIP 2............ 97
Combination instrument - setting the wheel
circumference (690 Enduro)........................................... 98
Checking the headlight setting........................................ 98
Adjusting the headlight range ......................................... 99
Removing the headlight mask with the headlight .............. 99
Installing the headlight mask with the headlight ............. 100
Changing the parking light bulb .................................... 101
Changing the headlight bulb......................................... 102
Changing the turn signal bulb ....................................... 103
30/ENGINE..................................................................... 104
Removing the engine ................................................... 104
Installing the engine .................................................... 106
30/DISASSEMBLING THE ENGINE................................... 110
Clamping engine into engine work stand ........................ 110
Draining the engine oil................................................. 110
Removing starter motor ................................................ 110
Removing valve cover................................................... 110
Removing the alternator cover....................................... 111
Removing spacer ......................................................... 111
Removing gear position sensor ...................................... 111
Removing oil filter ....................................................... 111
Removing thermostat ................................................... 112
Setting engine to ignition top dead center...................... 112
Removing water pump wheel ........................................ 112
Removing clutch cover ................................................. 113
Removing spacer and spring ......................................... 113
Removing spark plug ................................................... 113
Removing timing chain tensioner .................................. 114
Removing camshafts.................................................... 114
Removing cylinder head ............................................... 114
Removing piston.......................................................... 114
Removing rotor............................................................ 115
Removing timing chain rails ......................................... 115
Removing timing chain and timing chain sprocket .......... 116
Removing crankshaft position sensor ............................. 116
Removing clutch cage.................................................. 116
Removing primary gear................................................. 118
Removing starter drive ................................................. 118
Removing shift shaft.................................................... 118
Removing shift drum locating ....................................... 118
Removing locking lever ................................................ 119
Removing oil pumps .................................................... 119
Removing left engine case............................................ 119
Removing crankshaft and balancer shaft........................ 120
Removing transmission shafts....................................... 120
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 122
Work on the right section of the engine case .................. 122
Work on the left section of the engine case .................... 123
Work on the clutch cover.............................................. 124
Removing crankshaft bearing inner ring ......................... 125
Removing balancer shaft drive wheel ............................. 125
Changing the conrod bearing ........................................ 125
Checking crankshaft run-out at bearing pin .................... 127
Installing balancer shaft drive wheel.............................. 127
Installing crankshaft bearing inner ring.......................... 127
Measuring axial clearance of crankshaft and balancer
shaft .......................................................................... 128
Cylinder - Nikasil®coating ............................................ 128
Checking/measuring the cylinder................................... 129
Checking/measuring the piston ..................................... 129
Checking piston ring end gap........................................ 130
Checking piston/cylinder mounting clearance ................. 131
Checking oil pumps for wear......................................... 131
Replacing autodecompressor ........................................ 131
Preparing timing chain tensioner for installation ............. 132
Checking timing assembly ............................................ 133
Removing rocker arm ................................................... 133
Changing camshaft bearing .......................................... 133
Removing valves.......................................................... 134
Checking valves........................................................... 135
Checking valve springs ................................................. 135
Checking valve spring retainer ...................................... 135
Checking cylinder head ................................................ 135
Installing valves .......................................................... 136
Installing rocker arm.................................................... 137
Dismantling antihopping clutch .................................... 137
Checking the clutch..................................................... 138
Preassembling antihopping clutch................................. 139
Checking shift mechanism ........................................... 140
Preassembling shift shaft ............................................. 140
Disassembling the main shaft ....................................... 141
Dismantling countershaft ............................................. 142
Checking the transmission............................................ 143
Assembling the main shaft ........................................... 145
Assembling countershaft .............................................. 146
Checking electric starter drive....................................... 147
Removing freewheel..................................................... 148
Checking freewheel...................................................... 148
Installing freewheel ..................................................... 149
30/ASSEMBLING THE ENGINE ........................................ 150
Installing transmission shafts ....................................... 150
Installing crankshaft and balancer shaft......................... 151
Installing left engine case ............................................ 151
Installing oil pumps ..................................................... 152
Installing locking lever ................................................. 152
Installing shift drum locating ........................................ 152
Installing shift shaft..................................................... 153
Installing starter drive .................................................. 153
Installing primary gear ................................................. 153
Installing clutch cage................................................... 154
Installing crankshaft position sensor.............................. 155
Installing timing chain and timing chain sprocket ........... 155
Installing timing chain rails .......................................... 156
Installing rotor............................................................. 156
Adjusting crankshaft position sensor distance................. 156
Setting engine to top dead center.................................. 157
Installing piston .......................................................... 157
Installing cylinder head................................................ 158
Installing camshafts .................................................... 159
Installing timing chain tensioner ................................... 159
CONTENTS 4
Checking valve clearance ............................................. 160
Adjusting valve clearance ............................................. 160
Installing spark plug .................................................... 161
Installing spacer and spring.......................................... 161
Installing clutch cover.................................................. 161
Mounting water pump cover.......................................... 162
Installing thermostat.................................................... 162
Installing the oil filter .................................................. 162
Installing gear position sensor....................................... 163
Installing the spacer .................................................... 163
Installing oil screens.................................................... 164
Installing alternator cover ............................................. 164
Installing starter motor................................................. 165
Installing valve cover ................................................... 165
Taking engine off universal mounting rack ..................... 165
32/CLUTCH .................................................................... 166
Checking/rectifying the fluid level of the hydraulic
clutch ........................................................................ 166
35/WATER PUMP, COOLING SYSTEM .............................. 167
Draining the coolant .................................................... 167
Filling the cooling system............................................. 167
Checking the antifreeze and coolant level ...................... 168
Checking the coolant level............................................ 169
38/LUBRICATION SYSTEM .............................................. 170
Oil circuit ................................................................... 170
Checking the engine oil level ........................................ 170
Checking the engine oil pressure................................... 171
Changing the engine oil and filter, cleaning the oil
screens....................................................................... 172
Draining the engine oil................................................. 172
Removing the oil filter.................................................. 173
Installing the oil filter .................................................. 173
Cleaning the oil screens ............................................... 174
Filling up with engine oil.............................................. 175
Adding engine oil ........................................................ 175
39/IGNITION SYSTEM ..................................................... 176
Alternator - checking the stator winding......................... 176
Checking the spark plug connector................................ 176
Ignition coil - checking the secondary winding................ 177
41/THROTTLE VALVE BODY............................................. 178
Checking the basic setting of the motor drive ................. 178
Adjusting the basic setting of the motor drive................. 179
Flashing the EFI control unit and/or the EPT control
unit............................................................................ 182
Requesting the enabling code....................................... 183
Coding the EFI control unit and/or EPT control unit ........ 184
TECHNICAL DATA - ENGINE ............................................ 186
Capacity - engine oil .................................................... 186
Capacity - coolant........................................................ 186
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 187
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 189
TECHNICAL DATA - CHASSIS .......................................... 191
Lighting equipment ..................................................... 192
Capacity - fuel............................................................. 192
TECHNICAL DATA - FORK................................................ 193
690 Enduro ................................................................ 193
690 Enduro R ............................................................. 193
TECHNICAL DATA - SHOCK ABSORBER ........................... 194
690 Enduro ................................................................ 194
690 Enduro R ............................................................. 194
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 196
CLEANING/PROTECTIVE TREATMENT .............................. 198
Cleaning the motorcycle ............................................... 198
Protective treatment for winter operation ....................... 199
STORAGE ....................................................................... 200
Storage....................................................................... 200
Putting into operation after storage ............................... 200
SERVICE SCHEDULE....................................................... 201
Service schedule ......................................................... 201
WIRING DIAGRAM .......................................................... 202
Page 1 of 10 (690 Enduro) .......................................... 202
Page 2 of 10 (690 Enduro) .......................................... 204
Page 3 of 10 (690 Enduro) .......................................... 206
Page 4 of 10 (690 Enduro) .......................................... 208
Page 5 of 10 (690 Enduro) .......................................... 210
Page 6 of 10 (690 Enduro) .......................................... 212
Page 7 of 10 (690 Enduro) .......................................... 214
Page 8 of 10 (690 Enduro) .......................................... 216
Page 9 of 10 (690 Enduro) .......................................... 218
Page 10 of 10 (690 Enduro) ........................................ 220
Page 1 of 10 (690 Enduro R) ....................................... 222
Page 2 of 10 (690 Enduro R) ....................................... 224
Page 3 of 10 (690 Enduro R) ....................................... 226
Page 4 of 10 (690 Enduro R) ....................................... 228
Page 5 of 10 (690 Enduro R) ....................................... 230
Page 6 of 10 (690 Enduro R) ....................................... 232
Page 7 of 10 (690 Enduro R) ....................................... 234
Page 8 of 10 (690 Enduro R) ....................................... 236
Page 9 of 10 (690 Enduro R) ....................................... 238
Page 10 of 10 (690 Enduro R) ..................................... 240
SUBSTANCES................................................................. 242
AUXILIARY SUBSTANCES................................................ 244
SPECIAL TOOLS.............................................................. 246
STANDARDS................................................................... 258
INDEX ............................................................................ 259
MEANS OF REPRESENTATION 5
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Identifies a voltage measurement.
Identifies a current measurement.
Identifies a resistance measurement.
Formats used
The typographical and other formats used are explained below.
Specific name Indicates a proprietary name.
®
Name
Brand™ Identifies a trademark.
Identifies a protected name.
IMPORTANT NOTES 6
Warranty
The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record;
otherwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other
changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the repair manual.
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.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. Example: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Repair manual
– Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and service your motorcycle.
– This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.
LOCATION OF SERIAL NUMBERS 7
3.1Chassis number/type label (690 Enduro, 690 Enduro R EU, 690 Enduro R AUS/UK)
The chassis number is stamped on the right of the steering head.
The type label is on the right of the frame behind the steering head.
500006-01
3.2Chassis number/type label (690 Enduro R USA)
The chassis number is stamped on the right of the steering head.
The USA type label is on the right of the frame behind the steering head.
3.3Key number
500006-01
The Canada type label is on the right of the frame behind the steering head.
700218-01
The key number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
100179-10
3.4Engine number
The engine number is stamped on the left side of the engine under the engine
sprocket.
100211-10
LOCATION OF SERIAL NUMBERS 8
3.5Fork part number
The fork part number is stamped on the inner side of the fork stub.
800072-10
3.6Shock absorber part number
The shock absorber part number is on the right of the shock absorber.
100216-10
MOTORCYCLE 9
4.1Raising the motorcycle with the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
(690 Enduro)
– Raise the motorcycle using the underride guard under the motorcycle.
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.
800073-10
(690 Enduro R)
– Raise the motorcycle using the underride guard under the motorcycle.
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.
800089-10
4.2Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Remove the motorcycle from the lift stand and rest it on its side stand.
– Remove the lift stand.
4.3Raising the motorcycle with the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Mount the special tool on the footrest.
Work stand adapter (75029036000) ( p. 250)
300579-10
MOTORCYCLE 10
– Position the motorcycle upright, align the special tool and raise the motorcycle.
Work stand (62529055000) ( p. 249)
300201-10
4.4Removing the motorcycle from the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Secure the motorcycle against falling over.
– Remove the work stand and lean the vehicle on the side stand.
300201-10
– Remove the special tool.
300579-10
4.5Starting
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
MOTORCYCLE 11
– Turn the emergency OFF switch to the position .
– Switch on the ignition by turning the ignition key to position ON .
After you switch on the ignition, you can hear the fuel pump working for about
2 seconds. At the same time, the function test of the combination instrument
is run.
– Shift gear to neutral.
The green idling speed indicator lamp N lights up.
– Press the electric starter button .
B00103-10
Info
Do not press the electric starter button until the function test of the combination instrument is finished.
When starting, DO NOT open the throttle. If you open the throttle during the
starting procedure, fuel is not injected by the engine management system
and the engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds
before trying again.
This motorcycle is equipped with a safety start system. You can only start
the engine if the gearbox is in neutral or if the clutch is pulled when a
gear is engaged. If the side stand is folded out and you shift into gear and
release the clutch, the engine stops.
– Take the weight off the side stand and swing it back up with your foot as far as it
will go.
4.6Starting the motorcycle to make checks
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Info
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
– Turn the emergency OFF switch to the position .
– Shift gear to neutral.
– Switch on the ignition.
– Press the electric starter button .
Info
Do not open the throttle.
B00103-10
01/FORK, TRIPLE CLAMP 12
5.1Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Remove protection covers .
– Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
800074-10
(690 Enduro)
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
(690 Enduro R)
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
– Mount protection covers .
5.2Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork rebound behavior.
(690 Enduro)
– Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork
type.
100244-10
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
01/FORK, TRIPLE CLAMP 13
(690 Enduro R)
– Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork
type.
800090-10
5.3Bleeding the fork legs
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce
damping.
– Lean the motorcycle on the side stand.
(690 Enduro)
– Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
100248-10
800091-10
5.4Cleaning the dust boots of the fork legs
Info
Carry out this action on both fork legs.
(690 Enduro R)
– Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.
– Raise the motorcycle with the lift stand. ( p. 9)
– Loosen the fork protection. ( p. 14)
– Push dust boot of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
100293-10
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
01/FORK, TRIPLE CLAMP 14
– Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 245)
– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 14)
– Remove the motorcycle from the lift stand. ( p. 9)
5.5Loosening the fork protection
(690 Enduro)
– Remove screws and take off clamp.
– Remove screws on left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.
800075-10
(690 Enduro R)
– Remove screws and take off clamp.
– Remove screws on left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.
800092-10
5.6Positioning the fork protection
800075-11
800092-11
(690 Enduro)
– Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
– Position the brake line and wiring harness. Put the clamp on, mount and
tighten screws .
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
(690 Enduro R)
– Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
– Position the brake line and wiring harness. Put the clamp on, mount and
tighten screws .
– Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
01/FORK, TRIPLE CLAMP 15
5.7Removing fork legs
– Raise the motorcycle with the lift stand. ( p. 9)
– Tie the rear of the vehicle down.
– Remove screws .
– Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Carefully pull the brake caliper backwards from the brake disc.
Info
Do not pull the handbrake lever when the brake caliper is removed.
201332-10
– Loosen screws and screw .
– Unscrew screw about 6 turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking efficiency caused by damaged brake
discs.
– Always lay the wheel down in such a way that the brake disc is not dam-
201333-10
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
– Remove screws . Take the brake line and wiring harness out of the clamp.
aged.
201334-10
201335-10
201336-10
– Remove the screws of the wheel speed sensor . Hang the wheel speed sensor to
one side.
– Loosen screws of the triple clamp on both sides. Remove the fork legs from the
bottom.
01/FORK, TRIPLE CLAMP 16
– Remove screws . Remove the fork protector from above.
201337-10
5.8Installing the fork legs
– Slide on the fork protector from above and position it. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
201337-11
– Slide the fork legs into the triple clamps on both sides.
201336-11
201335-11
Info
The bleeder screws must face forwards.
The topmost milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
The upper fork projection must be the same on both sides.
– Tighten screws on both sides.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
– Position the wheel speed sensor. Mount and tighten screws .
Guideline
Screw, wheel speed sensor M4 2 Nm
(1.5 lbf ft)
– Position the brake line, wiring harness and clamp.
– Mount and tighten screws .
Loctite®243™
201334-11
01/FORK, TRIPLE CLAMP 17
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
– Clean screw and the wheel spindle.
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
201338-10
– Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 40 Nm
(29.5 lbf ft)
– Position the brake caliper and check that the brake linings are seated correctly.
– Mount and tighten screws .
Guideline
Screw, front brake caliper M8 25 Nm
Loctite®243™
(18.4 lbf ft)
– Unload the rear of the vehicle.
– Remove the motorcycle from the lift stand. ( p. 9)
5.9Servicing the fork
201332-11
– Pull the front brake and compress the fork powerfully a few times.
The fork legs straighten.
– Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
201333-11
Condition
The fork legs have been removed.
– Disassemble the fork legs. ( p. 18)
– Disassemble the cartridge. ( p. 20)
– Disassemble the tap compression. ( p. 22)
– Check the fork legs. ( p. 23)
– Assemble the tap compression. ( p. 25)
– Assemble the cartridge. ( p. 26)
– Assemble the fork legs. ( p. 27)
201241-01
01/FORK, TRIPLE CLAMP 18
5.10Disassembling the fork legs
Info
These operations are the same on both fork legs.
Condition
The fork legs have been removed.
– Remove protection cap .
– Note down the current state of the rebound and compression damping .
– Completely open the adjusters of the rebound and compression damping.
200736-10
– Clamp the fork leg in the area of the lower triple clamp.
Clamping stand (T1403S) ( p. 257)
200643-10
200737-10
200690-10
– Loosen the screw cover .
Info
The screw cover cannot be removed yet.
– Release the fork leg and clamp it with the fork stub.
Info
Use soft jaws.
– Push the outer tube downward.
– Pull the spring downward. Mount the special tool on the hexagon.
Open-end wrench (T14032) ( p. 256)
200738-10
Info
The preload spacers should be above the special tool.
01/FORK, TRIPLE CLAMP 19
– Clamp the special tool in the vise. Loosen the screw cover .
200739-10
– Remove screw cover with preload spacers .
– Remove the adjusting tube .
200648-12
– Pull the spring downward. Remove the special tool.
– Remove the spring.
200649-01
200650-01
200691-10
– Empty the fork oil.
Info
Pull out and push in the piston rod a few times to empty the cartridge.
– Clamp the fork leg with the fork stub.
– Loosen and remove the tap compression .
Info
Place a container underneath to catch any oil that may run out.
– Remove the cartridge.
200653-01
01/FORK, TRIPLE CLAMP 20
– Remove dust boot .
200735-10
– Remove lock ring .
Info
The lock ring has a beveled end where a screwdriver can be applied.
200656-01
– Heat up the outer tube in area of the lower sliding bushings.
Guideline
50 °C (122 °F)
200716-10
200658-01
– Pull the outer tube from the inner tube with a jerk.
Info
The lower sliding bushing must be pulled from its bearing seat.
– Remove the upper sliding bushing .
Info
Without using a tool, carefully pull the stack apart by hand.
– Take off the lower sliding bushing .
– Take off support ring .
– Take off seal ring .
– Take off lock ring .
– Take off dust boot .
– Unclamp the fork leg.
200659-11
5.11Disassembling the cartridge
Info
These operations are the same on both fork legs.
– Disassemble the fork legs. ( p. 18)
01/FORK, TRIPLE CLAMP 21
– Degrease the piston rod.
– Clamp the piston rod with the special tool.
Clamping stand (T14016S) ( p. 256)
– Remove fluid barrier from the piston rod.
200746-10
– Take piston rod out of the cartridge.
200747-10
– Take washer and spring seat off of the cartridge.
200748-10
200749-10
200697-10
– Degrease the cartridge and clamp it with the special tool.
Clamping stand (T14015S) ( p. 256)
– Heat the cartridge in area .
Guideline
50 °C (122 °F)
– Loosen and remove screw sleeve .
Info
This operation is not needed for further disassembly.
– Degrease the piston rod.
– Clamp the piston rod with the special tool.
Clamping stand (T14016S) ( p. 256)
– Remove nut .
– Completely remove shim stack .
200698-10
01/FORK, TRIPLE CLAMP 22
– Remove piston .
– Completely remove shim stack .
200699-10
– Remove spring .
– Loosen and remove tap rebound .
200700-10
– Remove spring .
– Remove valve of the rebound damping with the spring.
– Unclamp the piston rod.
200701-10
5.12Disassembling the tap compression
Info
These operations are the same on both fork legs.
200702-10
– Disassemble the fork legs. ( p. 18)
– Clamp the tap compression in a vise using soft jaws.
– Remove nut .
– Remove the spring.
– Remove washer .
– Remove piston .
– Remove shim stack .
200703-10
01/FORK, TRIPLE CLAMP 23
– Remove O-ring and seal ring from the tap compression.
– Unclamp the tap compression.
200704-10
5.13Checking the fork legs (690 Enduro)
Condition
Fork dismantled.
– Check the inner tube and the axle clamp for damage.
» If damage is found:
– Replace the inner tube.
200728-10
200684-10
200685-10
– Measure the external diameter of the inner tube in several places.
External diameter of inner tube 47.975… 48.005 mm (1.88878…
1.88996 in)
» If the measured value is less than the specified value:
– Replace the inner tube.
– Measure the run-out of the inner tube.
Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in)
» If the measured value is greater than the specified value:
– Replace the inner tube.
– Check the outer tube for damage.
» If damage is found:
– Replace the outer tube.
200632-10
01/FORK, TRIPLE CLAMP 24
– Check the surface of the sliding bushings.
» If the bronze-colored layer under sliding layer is visible:
– Replace the sliding bushings.
200665-10
– Check the spring length.
Guideline
Spring length with preload spacer(s) 472 mm (18.58 in)
» If the measured value is greater than the specified value:
– Reduce the strength of the pretensioning bushes.
» If the measured value is less than the specified value:
– Increase the strength of the preload spacers.
200666-10
5.14Checking the fork legs (690 Enduro R)
Condition
Fork dismantled.
– Check the inner tube and the axle clamp for damage.
» If damage is found:
– Replace the inner tube.
200728-10
200684-10
200685-10
– Measure the external diameter of the inner tube in several places.
External diameter of inner tube 47.975… 48.005 mm (1.88878…
1.88996 in)
» If the measured value is less than the specified value:
– Replace the inner tube.
– Measure the run-out of the inner tube.
Run-out of inner tube ≤ 0.20 mm (≤ 0.0079 in)
» If the measured value is greater than the specified value:
– Replace the inner tube.
01/FORK, TRIPLE CLAMP 25
– Check the outer tube for damage.
» If damage is found:
– Replace the outer tube.
200632-10
– Check the surface of the sliding bushings.
» If the bronze-colored layer under sliding layer is visible:
– Replace the sliding bushings.
200665-10
– Check the spring length.
Guideline
Spring length with preload spacer(s) 495 mm (19.49 in)
200666-10
5.15Assembling the tap compression
Info
These operations are the same on both fork legs.
200704-11
» If the measured value is greater than the specified value:
– Reduce the strength of the pretensioning bushes.
» If the measured value is less than the specified value:
– Increase the strength of the preload spacers.
– Clamp the tap compression in a vise using soft jaws.
– Mount O-ring and seal ring .
– Lubricate the O-ring.
Lubricant (T158) ( p. 244)
– Mount shim stack .
Info
Mount with the smaller shims facing downward.
200705-10
– Mount piston with the O-ring.
Info
The side with the larger inside diameter faces upward.
– Lubricate the O-ring of the piston.
Fork oil (SAE 5) ( p. 243)
01/FORK, TRIPLE CLAMP 26
– Mount washer .
– Mount spring with the tighter coil facing downward.
– Mount and tighten the nut .
Guideline
Tap compression nut M6x0.5 3 Nm (2.2 lbf ft)
Info
Washer must be movable against the spring force.
200706-10
5.16Assembling the cartridge
Info
These operations are the same on both fork legs.
– Lock the nut using a punch.
– Unclamp the tap compression.
– Clamp the piston rod.
Clamping stand (T14016S) ( p. 256)
– Mount valve of the rebound damping with the spring and O-ring.
– Lubricate the O-ring.
200715-10
200718-10
200719-10
Lubricant (T158) ( p. 244)
– Mount spring .
– Lubricate the O-ring of tap rebound .
Lubricant (T158) ( p. 244)
– Mount and tighten the tap compression.
Guideline
Tap rebound M9x1 18 Nm
(13.3 lbf ft)
– Position spring .
– Mount shim stack .
Info
Mount with the smaller shims facing downward.
– Press the shim stack down against the spring force.
Info
The shim stack must be pressed down over the collar.
– Mount piston with the piston ring.
Loctite®2701
200720-10
Info
The side with the larger inside diameter should face downward.
– Mount shim stack .
Info
Align the triangular plates exactly with the opening of the piston.
– Mount and tighten the nut .
Guideline
Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft)
Info
Mount the nut with the collar facing downward.
01/FORK, TRIPLE CLAMP 27
– Lock the nut using a punch.
– Degrease the cartridge and clamp it with the special tool.
Clamping stand (T14015S) ( p. 256)
– Mount and tighten screw sleeve .
Guideline
Screw sleeve M29x1 46 Nm
(33.9 lbf ft)
200749-11
– Mount washer and spring seat .
200748-11
– Slide piston rod into the cartridge.
Loctite®241
200747-11
200746-11
5.17Assembling the fork legs (690 Enduro)
Info
These operations are the same on both fork legs.
– Screw on fluid barrier as far as it will go.
Info
The fluid barrier must be tightened as much as possible. Do not use tools.
– Check the fork legs. ( p. 23)
– Assemble the cartridge. ( p. 26)
– Assemble the tap compression. ( p. 25)
– Clamp the inner tube with the axle clamp.
– Mount the special tool.
Protecting sleeve (T1401) ( p. 255)
200669-10
– Grease and push on dust boot .
Lubricant (T511) ( p. 244)
Info
Always replace the dust boot, the seal ring, the lock ring, and the support
ring.
Mount the sealing lip with the spring expander facing downward.
01/FORK, TRIPLE CLAMP 28
– Push on lock ring .
– Grease and push on seal ring .
Lubricant (T511) ( p. 244)
Info
Sealing ring downward, open side upward.
– Push on support ring .
– Remove the special tool.
– Sand the edges of the sliding bushes with 600-grit sandpaper, then clean and
grease them.
Fork oil (SAE 5) ( p. 243)
200670-10
– Push on the lower sliding bushing .
– Mount the upper sliding bushing .
200671-10
200723-10
Info
Without using a tool, carefully pull the stack apart by hand.
– Push on the outer tube.
– Heat up the outer tube in area of the lower sliding bushings.
Guideline
50 °C (122 °F)
– Hold the lower sliding bushing with the longer side of the special tool.
Assembly tool (T1402S) ( p. 256)
– Press on the outer tube as far as it will go.
– Position the support ring.
– Hold the seal ring with the shorter side of the special tool.
Assembly tool (T1402S) ( p. 256)
– Press on the outer tube as far as it will go.
200724-10
200656-11
– Mount lock ring .
Info
The lock ring must engage audibly.
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