Content .. 6 7 8 9 ..

KTM (690 Enduro EU, 690 Enduro AUS/UK, 690 Enduro USA). Manual - part 8

07/FUEL TANK, SEAT, TRIM

300563-10

– Lift the rear fairing.
– Remove screws



300564-10

– Remove screw



– Repeat the operation on the opposite side.
– Swing the rear end upwards and secure it.

302607-10

– Remove screws



– Pull out the fuel pump.

302608-10

– Remove hose clamps



– Remove fuel filter



302609-10

– Press lock



– Remove fuel pump housing



302610-10

– Change fuel screen



– Mount the fuel pump housing.

07/FUEL TANK, SEAT, TRIM

302608-11

– Mount fuel filter



Arrow



points away from the fuel pump.

– Mount hose clamps



Hose clamp pliers (60029057000) (

p. 214)

302607-10

– Position the fuel pump.
– Mount and tighten screws



Guideline

Screw, fuel pump

6 Nm (4.4 lbf ft)

300564-10

– Position the rear end.
– Mount and tighten screw



Guideline

Screw, fuel tank, bottom

20 Nm
(14.8 lbf ft)

– Repeat the operation on the opposite side.

300563-10

– Lift the rear fairing.
– Mount and tighten screws



Guideline

Screw, main silencer
holder on fuel tank

25 Nm
(18.4 lbf ft)

Loctite

243™

300562-10

– Mount and tighten screws



Guideline

Screw, side cover

2 Nm (1.5 lbf ft)

– Disconnect the battery. (

p. 73)

09/FRONT WHEEL

12.1

Removing the front wheel

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

800078-10

– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

800079-10

– Remove screw



– Loosen screw



100263-10

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

the fork.

Info

Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.

800080-10

– Remove distance bushings



12.2

Installing the front wheel

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.

800080-11

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

– Replace the wheel bearing.

– Clean and grease the shaft seal rings



and bearing surface



of the distance

bushings.

Long-life grease (

p. 210)

– Insert the spacers.

09/FRONT WHEEL

800079-11

– 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)

– Activate the hand brake lever multiple times until the brake linings are in contact

with the brake disc.

– Remove the motorcycle from the lift stand. ( p. 9)
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Tighten screws



Guideline

Screw, fork stub

15 Nm
(11.1 lbf ft)

12.3

Checking the tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

400695-01

– Remove the dust cap.
– Check the tire air pressure when the tires are cold.

Tire air pressure, offroad, single rider

Front

1.5 bar (22 psi)

Rear

1.5 bar (22 psi)

Tire air pressure, road, solo

Front

1.8 bar (26 psi)

Rear

1.8 bar (26 psi)

Tire air pressure with passenger / fully loaded

Front

2.0 bar (29 psi)

Rear

2.2 bar (32 psi)

» If the tire pressure does not meet specifications:

– Correct the tire pressure.

– Mount the dust cap.

12.4

Checking the tire condition

Warning

Danger of accidents Uncontrollable handling characteristic caused by a flat tire.
– For your own safety, have damaged tires changed immediately.

Warning

Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.

Warning

Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be

roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not
achieved until the tires have been run in.

09/FRONT WHEEL

Info

The type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.

400602-10

– Check the front and rear tires for cuts, run-in objects and other damage.

» If the tires exhibit cuts, run-in objects or other damage:

– Change the tires.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth

≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum permissible depth:

– Change the tires.

– Check the age of the tires.

Info

The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the

DOT marking. The first two digits refer

to the week of manufacture and last two digits refer to the year of manufac-
ture.
KTM recommends that the tires are changed regardless of the actual wear,
at the latest after five years.

» If a tire is more than five years old:

– Change the tires.

12.5

Checking the brake discs

Warning

Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay.

400406-10

– Check the thickness of the front and rear brake discs in several places to ensure

that it conforms to measurement



Info

Wear reduces the thickness of the brake disc at the contact surface



the brake disc.

Brake discs - wear limit

Front

4.5 mm (0.177 in)

Rear

3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

– Replace the brake disc.

– Check the front and rear brake discs for damage, cracks, and deformation.

» If damage, cracks, or deformation are visible on the brake disc:

– Replace the brake disc.

10/REAR WHEEL

13.1

Removing rear wheel

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

100267-10

– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

– Remove nut



. Remove chain adjuster



– Holding the rear wheel, withdraw the wheel spindle



100268-01

– Push the rear wheel forwards as far as possible and take the chain off the rear

sprocket.

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.

– Take the rear wheel out of the swing arm.

Info

Do not operate the foot brake when the rear wheel is removed.

13.2

Installing the rear wheel

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.

Warning

Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.

– Check the rear hub rubber dampers. ( p. 70)

100269-10

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

– Replace the wheel bearing.

– Remove bushing



. Clean and grease the working surfaces of the bushing and

shaft seal ring



Long-life grease (

p. 210)

– Clean and grease the thread of the wheel spindle and nut



Long-life grease (

p. 210)

– Install the rubber damper and rear sprocket carrier in the rear wheel.
– Place the rear wheel in the swingarm and bring the brake disc on the brake caliper

into contact.

100270-10

– Push the rear wheel forward as far as possible and lay the chain on the rear

sprocket.

– Install the wheel spindle, the chain adjusters and the nut.

Guideline

In order that the rear wheel is correctly aligned, the markings on the left and
right chain adjusters must be in the same position relative to the reference
marks



Info

Mount the left and right chain adjusters



in the same position.

10/REAR WHEEL

– Tighten nut



Guideline

Nut, rear wheel spindle

M25x1.5

90 Nm
(66.4 lbf ft)

– Operate the foot brake lever repeatedly until the brake linings are in contact with

the brake disc and there is a pressure point.

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

13.3

Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

100249-10

– Lean the motorcycle on the side stand.
– Shift gear to neutral.
– Push the chain upward at a distance



from the chain sliding guard and determine

the chain tension



Info

The upper chain section



must be taut.

Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension

5 mm (0.2 in)

Distance to chain sliding guard

30 mm (1.18 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension. (

p. 67)

13.4

Adjusting the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

– Check the chain tension. (

p. 67)

10/REAR WHEEL

100250-10

– Loosen nut



– Loosen nuts



– Adjust the chain tension by turning adjusting screws



on the left and right.

Guideline

Chain tension

5 mm (0.2 in)

Turn the left and right adjusting screws



so that the markings on the left

and right chain adjusters



are in the same position relative to the reference

marks



. The rear wheel is then correctly aligned.

Info

The upper chain section must be taut.
Chain wear is not always even, so you should check this setting at different
chain positions.

– Tighten nuts



– Make sure that the chain adjusters



are installed correctly on adjusting screws



– Tighten nut



Guideline

Nut, rear wheel spindle

M25x1.5

90 Nm
(66.4 lbf ft)

Info

The wide adjustment range of the chain adjusters (30 mm (1.18 in))
enables different secondary transmissions with the same chain length.
The chain adjusters



can be turned through 180°.

13.5

Adjusting chain guide

100299-10

– Remove screws



and



. Take off the chain guide.

Condition

Number of teeth: ≤ 44 teeth
– Insert nut



in hole



. Position the chain guide.

– Mount and tighten screws



and



Guideline

Remaining screws, chassis

10 Nm
(7.4 lbf ft)

Condition

Number of teeth: ≥ 45 teeth
– Insert nut



in hole



. Position the chain guide.

– Mount and tighten screws



and



Guideline

Remaining screws, chassis

10 Nm
(7.4 lbf ft)

13.6

Checking the chain, rear sprocket and engine sprocket

100132-10

– Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket and engine sprocket are worn:

– Replace the rear sprocket or engine sprocket.

Info

The engine sprocket, rear sprocket and chain should always be
replaced together.

Content .. 6 7 8 9 ..