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KTM (690 Enduro EU, 690 Enduro AUS/UK, 690 Enduro USA). Manual - part 2

01/FORK, TRIPLE CLAMP

100248-10

– 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.

5.4

Cleaning the dust boots of the fork legs

– Raise the motorcycle with the lift stand. ( p. 9)
– Loosen the fork protection. (

p. 13)

100293-10

– 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.

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 and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray (

p. 211)

– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. (

p. 13)

– Remove the motorcycle from the lift stand. ( p. 9)

5.5

Loosening the fork protection

800075-10

– 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.

5.6

Positioning the fork protection

800075-11

– Position the fork protection on the left fork leg. Mount and tighten screws



Guideline

Remaining screws, chassis

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

10 Nm (7.4 lbf ft)

01/FORK, TRIPLE CLAMP

5.7

Removing fork legs

– Raise the motorcycle with the lift stand. ( p. 9)
– Tie the rear of the vehicle down.

201332-10

– 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.

201333-10

– 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-

aged.

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

the fork.

201334-10

– Remove screws



. Take the brake line and wiring harness out of the clamp.

201335-10

– Remove the screws of the wheel speed sensor



. Hang the wheel speed sensor to

one side.

201336-10

– Loosen screws



of the triple clamp on both sides. Remove the fork legs from the

bottom.

01/FORK, TRIPLE CLAMP

201337-10

– Remove screws



. Remove the fork protector from above.

5.8

Installing the fork legs

201337-11

– Slide on the fork protector from above and position it. Mount and tighten screws



Guideline

Remaining screws, chassis

10 Nm (7.4 lbf ft)

201336-11

– Slide the fork legs into the triple clamps on both sides.

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

17 Nm
(12.5 lbf ft)

Screw, bottom triple clamp

12 Nm (8.9 lbf ft)

201335-11

– Position the wheel speed sensor. Mount and tighten screws



Guideline

Screw, wheel speed sensor M4

2 Nm
(1.5 lbf ft)

Loctite

243™

201334-11

– Position the brake line, wiring harness and clamp.
– Mount and tighten screws



01/FORK, TRIPLE CLAMP

201338-10

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.

– Clean screw



and the wheel spindle.

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw



Guideline

Screw, front wheel spindle

M24x1.5

40 Nm
(29.5 lbf ft)

201332-11

– Position the brake caliper and check that the brake linings are seated correctly.
– Mount and tighten screws



Guideline

Screw, front brake caliper

25 Nm
(18.4 lbf ft)

Loctite

243™

– Unload the rear of the vehicle.
– Remove the motorcycle from the lift stand. ( p. 9)

201333-11

– Pull the front brake and compress the fork powerfully a few times.

The fork legs straighten.

– Tighten screws



Guideline

Screw, fork stub

15 Nm
(11.1 lbf ft)

5.9

Servicing the fork

Condition
The fork legs have been removed.

201241-01

– Disassemble the fork legs. (

p. 17)

– Disassemble the cartridge. (

p. 19)

– Disassemble the tap compression. ( p. 21)
– Check the fork legs. (

p. 22)

– Assemble the tap compression. ( p. 23)
– Assemble the cartridge. (

p. 24)

– Assemble the fork legs. (

p. 25)

01/FORK, TRIPLE CLAMP

5.10

Disassembling the fork legs

Info

These operations are the same on both fork legs.

Condition
The fork legs have been removed.

200689-10

– Remove protection cap



– Note down the current state of the rebound



and compression damping



– Completely open the adjusters of the rebound and compression damping.

200643-10

– Clamp the fork leg in the area of the lower triple clamp.

Clamping stand (T1403S) (

p. 222)

200644-12

– Loosen the screw cover



Info

The screw cover cannot be removed yet.

200690-10

– Release the fork leg and clamp it with the fork stub.

Info

Use soft jaws.

200646-12

– Push the outer tube downward.
– Pull the spring downward. Mount the special tool on the hexagon.

Open-end wrench (T14032) (

p. 222)

Info

The preload spacers



should be above the special tool.

01/FORK, TRIPLE CLAMP

200647-12

– Clamp the special tool in the vise. Loosen the screw cover



200648-12

– Remove screw cover



with preload spacers



– Remove the adjusting tube



200649-01

– Pull the spring downward. Remove the special tool.
– Remove the spring.

200650-01

– Empty the fork oil.

Info

Pull out and push in the piston rod a few times to empty the cartridge.

200691-10

– 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.

200653-01

– Remove the cartridge.

01/FORK, TRIPLE CLAMP

200735-10

– Remove dust boot



200656-01

– Remove lock ring



Info

The lock ring has a beveled end where a screwdriver can be applied.

200716-10

– Heat up the outer tube in area



of the lower sliding bushings.

Guideline

50 °C (122 °F)

– Pull the outer tube from the inner tube with a jerk.

Info

The lower sliding bushing



must be pulled from its bearing seat.

200658-01

– Remove the upper sliding bushing



Info

Without using a tool, carefully pull the stack apart by hand.

200659-11

– 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.

5.11

Disassembling the cartridge

Info

These operations are the same on both fork legs.

– Disassemble the fork legs. (

p. 17)

01/FORK, TRIPLE CLAMP

200693-10

– Clamp the special tool in a vise.

Pin (T605) (

p. 223)

– Attach cartridge



using the drilled holes.

200694-10

– Loosen and remove screw sleeve



200695-10

– Pull piston rod



out of cartridge



– Clamp the piston rod. Remove fluid barrier



Clamping stand (T14016S) (

p. 222)

200696-10

– Take screw sleeve



off of the cartridge along with the washer and spring seat.

200697-10

– Degrease the piston rod.
– Clamp the piston rod with the special tool.

Clamping stand (T14016S) (

p. 222)

200698-10

– Remove nut



– Completely remove shim stack



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