Content .. 3 4 5 6 ..

KTM (690 Enduro EU, 690 Enduro AUS/UK, 690 Enduro USA). Manual - part 5

04/SHOCK ABSORBER, SWINGARM

300565-10

– Loosen screw



– Remove screw



– Remove screw



300566-10

– Swing the rear end upwards.
– Lift shock absorber



upwards and remove.

8.10

Installing the shock absorber

300566-11

– Swing the rear end upwards and insert shock absorber



from above.

300565-11

– Mount screw



but do not tighten yet.

– Mount and tighten screw



Guideline

Screw, bottom shock
absorber

M10

45 Nm
(33.2 lbf ft)

Loctite

243™

– Tighten screw



Guideline

Screw, top shock absorber

M10

45 Nm
(33.2 lbf ft)

Loctite

243™

04/SHOCK ABSORBER, SWINGARM

300564-11

– Mount and tighten screw



Guideline

Screw, fuel tank, bottom

20 Nm
(14.8 lbf ft)

– Repeat the operation on the opposite side.

300563-11

– Lift the rear fairing.
– Mount and tighten screws



Guideline

Screw, main silencer
holder on fuel tank

25 Nm
(18.4 lbf ft)

Loctite

243™

300562-11

– Mount and tighten screws



Guideline

Screw, side cover

2 Nm (1.5 lbf ft)

– Mount the side cover. (

p. 59)

– Remove the motorcycle from the work stand. ( p. 10)

8.11

Servicing the shock absorber

Danger

Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided.

Condition
The shock absorber has been removed.

201239-01

– Remove the spring. (

p. 39)

– Dismantle the damper. (

p. 39)

– Disassemble the piston rod. (

p. 40)

– Check the damper. (

p. 41)

– Remove the heim joint. (

p. 42)

– Install the heim joint. (

p. 43)

– Assemble the piston rod. (

p. 44)

– Assemble the damper. (

p. 45)

– Install the spring. (

p. 49)

04/SHOCK ABSORBER, SWINGARM

8.12

Removing the spring

Condition
The shock absorber has been removed.

300580-10

– Clamp the shock absorber in the vise using soft jaws for protection.
– Measure and note spring length in preloaded state.
– Loosen retaining ring



and the adjusting ring with the special tool.

Hook wrench (T106S) (

p. 220)

Hook wrench (T157S) (

p. 223)

– Turn the retaining ring and adjusting ring until the spring is fully relieved of ten-

sion.

300581-10

– Press down the spring with the special tool.

Spring compressor (T101S) (

p. 220)

– Remove spring retainer



300582-10

– Take off spring



with the retaining ring and adjusting ring



8.13

Dismantling the damper

– Remove the spring. (

p. 39)

300583-10

– Establish and note the current state of the rebound damping and compression

damping.

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



– Press in valve needle



The pressurized nitrogen escapes.

300584-10

– Remove locking cap



04/SHOCK ABSORBER, SWINGARM

300585-10

– Press in seal ring retainer



. Remove lock ring



Info

Do not scratch the inner surface.

300586-10

– Remove screw



. Drain the oil.

300587-10

– Remove the piston rod. Drain the remaining oil.

300588-10

– Remove compression damping adjuster



. Remove the spring, sleeve and piston.

300589-10

– Push back membrane cover



– Remove lock ring



– Remove membrane



8.14

Disassembling the piston rod

– Dismantle the damper. (

p. 39)

300540-10

– Clamp the piston rod with the heim joint in a vise.
– Remove nut



04/SHOCK ABSORBER, SWINGARM

300541-10

– Remove supporting plate



and rebound shim stack



together with piston



Info

Thread the rebound shim set on a screwdriver and set the parts down
together.

200572-11

– Remove compression shim stack



with supporting plate



Info

Thread the compression shim stack on a screwdriver and set the parts down
together.

300542-10

– Remove seal ring retainer



300543-10

– Remove locking cap



and rubber buffer



8.15

Checking the damper

Condition
The damper has been disassembled.

300596-10

– Measure the inside diameter at both ends and in the center of the damper car-

tridge.

Damper cartridge

Minimum diameter

46.10 mm (1.815 in)

» If the measured value is greater than the specified value:

– Change the damper cartridge.

– Check the damper cartridge for damage and wear.

» If there is damage or wear:

– Change the damper cartridge.

04/SHOCK ABSORBER, SWINGARM

300554-10

– Measure the diameter of the piston rod.

Piston rod

Diameter

≥ 17.95 mm (≥ 0.7067 in)

» If the specification is not reached:

– Change the piston rod.

– Measure the run-out of the piston rod.

Piston rod

Run-out

≤ 0.03 mm (≤ 0.0012 in)

» If the measured value is greater than the specified value:

– Change the piston rod.

– Check the piston rod for damage and wear.

» If there is damage or wear:

– Change the piston rod.

300460-01

– Check the heim joint for damage and wear.

» If there is damage or wear:

– Change the heim joint.

8.16

Removing the heim joint

Condition
The shock absorber has been removed.

200577-10

– Clamp the shock absorber in the vise using soft jaws for protection.
– Remove collar bushing



of the heim joint.

Pin (T120) (

p. 220)

– Turn over the shock absorber and remove collar bushing



of the heim joint.

Pin (T120) (

p. 220)

200578-10

– Remove seal rings



on both sides.

04/SHOCK ABSORBER, SWINGARM

200579-10

– Remove lock rings



on both sides.

200580-10

– Place special tool



underneath and press out the heim joint with special tool



Pressing tool (T1207S) (

p. 221)

8.17

Installing the heim joint

200581-10

– Place special tool



underneath and press in the heim joint as far as the center

using special tool



Pressing tool (T1206) (

p. 221)

Pressing tool (T129) (

p. 221)

200579-11

– Mount lock rings



on both sides.

200578-11

– Mount seal rings



on both sides and grease them.

Lubricant (T158) (

p. 210)

200582-10

– Press in both collar sleeves



of the heim joint.

04/SHOCK ABSORBER, SWINGARM

8.18

Assembling the piston rod

– Check the damper. (

p. 41)

300543-11

– Clamp the piston rod with the heim joint in a vise.
– Mount rubber buffer



and locking cap



300548-10

– Position special tool



on the piston rod.

Mounting sleeve (T1515) (

p. 223)

– Grease the seal ring and push seal ring retainer



on to the piston rod.

Lubricant (T625) (

p. 211)

– Remove the special tool.

200572-11

– Mount supporting plate



with the rounded side facing downward.

– Mount the compression shim stack



with the smaller shims facing downward.

300547-10

– Sand both sides of the piston on a surface plate using 1200-grit sandpaper.
– Clean the piston.
– Assemble the piston.

Info

The piston is the same on both sides.

300541-11

– Mount the rebound shim stack



with the smaller shims facing upward.

– Install supporting plate



300540-11

– Mount and tighten nut



Guideline

Piston rod nut

M12x1

40 Nm
(29.5 lbf ft)

Content .. 3 4 5 6 ..