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KTM (690 Enduro EU, 690 Enduro AUS/UK, 690 Enduro USA). Manual - part 16

30/ENGINE - WORK ON INDIVIDUAL PARTS

125

400375-10

– Check the sealing area of the cylinder for distortion using a straight edge and the

special tool.

Feeler gauge (59029041100) (

p. 214)

Cylinder/cylinder head - sealing area
distortion

≤ 0.10 mm (≤ 0.0039 in)

» If the measured value does not equal the specified value:

– Change the cylinder head.

400373-10

– Check sealing seat



of the valves.

Valve - sealing seat width

Intake

1.60 mm (0.063 in)

Valve - sealing seat width

Exhaust

2.00 mm (0.0787 in)

» If the measured value does not equal the specified value:

– Machine the valve seat.

– Blow compressed air through all oil holes and check that they are clear.

19.27

Installing valves

300118-01

– Position the valve spring cap



. Install new valve stem seals



– Install the valves



according to their normal built-in position.

– Install the valve springs



and the spring retainers.

300116-11

– Pretension the valve springs using the special tool.

Valve spring compressor (59029019000) (

p. 213)

Valve spring mounting device (78029060000) (

p. 220)

300115-11

– Mount valve keys.

Info

When mounting the valve keys, check that they are seated correctly; prefer-
ably, fix the valve keys to the valve with a little grease.

– Place shims



into the valve spring retainers according to the installation position.

30/ENGINE - WORK ON INDIVIDUAL PARTS

126

19.28

Installing rocker arm

300114-11

– Position the rocker arm



and push in the rocker arm shafts



Info

Make sure that the tapped hole of the rocker arm shaft is positioned facing
outwards.
The small drill hole and the flat surface must point upwards.

300113-11

– Install and tighten the screws



of the rocker arm shafts.

Guideline

Screw, rocker arm shaft

12 Nm (8.9 lbf ft)

19.29

Dismantling antihopping clutch

300120-10

– Clamp the clutch



in a vise.

Info

Use soft jaws.

– Carefully loosen and gradually remove the special tool



300121-10

– Take the clutch out of the vise and lay it on a clean workbench with the outer

clutch hub



facing down.

– Take the inner clutch hub



and release springs



out of the outer clutch hub



300122-10

– Take off the clutch disks



from the inner clutch hub.

– Remove pretension ring



and support ring



– Clean all parts well.
– Check the clutch. (

p. 127)

30/ENGINE - WORK ON INDIVIDUAL PARTS

127

19.30

Checking the clutch

– Dismantle the antihopping clutch. ( p. 126)

300123-01

– Check pressure piece



for damage and wear.

» If there is damage or wear:

– Replace the pressure piece.

– Check axial bearing



for damage and wear.

» If there is damage or wear:

– Change the axial bearing.

– Place push rod



on a level surface and check it for run-out.

» If there is run-out:

– Change the push rod.

– Check the length of clutch springs



Clutch spring - length

31.5… 33.5 mm (1.24… 1.319 in)

» If the clutch spring length is less than the specified value:

– Change all clutch springs.

– Check the contact surface of pressure cap



for damage and wear.

» If there is damage or wear:

– Change the pressure cap.

– Check the contact surfaces of the clutch facing discs in the outer clutch hub



for wear.

Clutch cage - contact surface of clutch facing discs

≤ 0.5 mm (≤ 0.02 in)

» If the contact surface is very worn:

– Change the clutch facing discs and the outer clutch hub.

– Check needle bearing



and supporting plate



for damage and wear.

» If there is damage or wear:

– Replace the needle bearing and supporting plate.

– Check intermediate discs



for damage and wear.

30/ENGINE - WORK ON INDIVIDUAL PARTS

128

» If the intermediate discs are not level or are pitted:

– Replace all intermediate discs.

– Check clutch facing discs



for discoloration and scoring.

» If there is discoloration or scoring:

– Change all clutch facing discs.

– Check the thickness of clutch facing discs



Clutch facing disc - thickness

≥ 2.5 mm (≥ 0.098 in)

» If the clutch facing disc does not meet specifications:

– Change all clutch facing discs.

– Check stepped washer



for damage and wear.

» If there is damage or wear:

– Replace the stepped washer.

– Check half washers



for damage and wear.

» If there is damage or wear:

– Replace the half washers.

– Check inner clutch hub



for damage and wear.

» If there is damage or wear:

– Replace the inner clutch hub.

– Check the outer clutch hub



for damage and wear.

» If there is damage or wear:

– Replace the outer clutch hub.

– Preassemble the antihopping clutch. ( p. 128)

19.31

Preassembling antihopping clutch

300123-10

– Lubricate the clutch discs thoroughly.
– Push the support ring



and the pretension ring



on to the outer clutch hub.

Info

The pretension ring must be installed so that it is flush with the inner
edge



on the support ring.

300124-10

– Position the trimmed clutch facing disc with the notch for the pretension ring on

the outer clutch hub.

– Beginning with a clutch disc, position all further clutch facing discs and clutch

discs alternately.

– Position the release springs



300125-10

– Push on the outer clutch hub



and pay attention to the markings.

The arrow



of the outer clutch hub must point to the notch



of the inner

clutch hub.

– Push the two clutch hubs firmly together and have an assistant screw in the special

tool.

Assembly screws (75029033000) (

p. 216)

Info

Apply the special tool with the hand only, do not use another tool.
Apply the special tool only firmly enough to all the clutch discs to be turned
against each other since they still have to be aligned for mounting in the
clutch cage.

30/ENGINE - WORK ON INDIVIDUAL PARTS

129

19.32

Checking shift mechanism

300120-01

– Check the shift forks



(see



) for damage and wear (visual check).

» If there is damage or wear:

– Change the shift fork and the idler/fixed gear pair.

– Check shift grooves



of shift drum



for wear.

» If the shift groove is worn:

– Change the shift roller.

– Check the seat of the shift drum in the bearings



» If the shift roller is not seated correctly:

– Replace the shift drum and/or the bearing.

– Check bearing



for stiffness and wear.

» If the bearings do not move freely or are worn:

– Replace the bearings.

– Check the needle bushing



for stiffness and wear.

» If the needle bushing does not move freely or is worn:

– Replace the needle bushing.

– Check the shift rail



on a flat surface for run-out.

» If there is run-out:

– Change the shift rail.

– Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.

» If there is scoring or corrosion, or if the shift fork is stiff:

– Change the shift rail.

– Check sliding plate



in contact areas



for wear.

» If the sliding plate is worn:

– Change the sliding plate.

– Check return surface



on the sliding plate for wear.

» If deep notches are present:

– Change the sliding plate.

– Check guide pin



for looseness and wear.

» If the guide pin is loose and/or worn:

– Change the sliding plate.

– Preassemble the shift shaft. (

p. 129)

300122-01

– Check the clearance



between the sliding plate and the shift quadrant.

Shift shaft - play in sliding plate/shift
quadrant

0.40… 0.80 mm (0.0157…
0.0315 in)

» If the measured value does not equal the specified value:

– Change the sliding plate.

19.33

Preassembling shift shaft

300154-01

– Fix the short end of the shift shaft in a vise.

Guideline

Use soft jaws.

– Mount sliding plate



with the guide pin facing down and attach the guide pin to

the shift quadrant.

– Mount preload spring



– Push on spring guide



, push return spring



over the spring guide with the offset

end facing upward and lift the offset end over abutment bolt



– Mount stop disk



30/ENGINE - WORK ON INDIVIDUAL PARTS

130

19.34

Disassembling the main shaft

0303

300127-03

– Fix the main shaft in the vise with the geared end facing downward.

Guideline

Use soft jaws.

– Remove stop disk



and second-gear fixed gear



– Remove the sixth-gear idler gear



– Remove the split needle bearing



and stop disk



– Remove lock ring



– Remove the third/fourth-gear sliding gear



– Remove lock ring



– Remove stop disk



and the fifth-gear idler gear



– Remove the split needle bearing



19.35

Dismantling countershaft

300128-01

– Fix the countershaft in the vise with the geared end facing downward.

Guideline

Use soft jaws

30/ENGINE - WORK ON INDIVIDUAL PARTS

131

– Remove stop disk



and the first-gear idler gear



– Remove needle bearing



and stop disk



– Remove the fifth-gear sliding gear



and lock ring



– Remove stop disk



and the third-gear idler gear



– Remove the needle bearing



and the fourth-gear idler gear



– Remove needle bearing



and stop disk



– Remove lock ring



and the sixth-gear sliding gear



– Remove lock ring



and stop disk



– Remove the second-gear idler gear



and needle bearing



19.36

Checking the transmission

– Disassemble the main shaft. (

p. 130)

– Dismantle the countershaft. (

p. 130)

500174-01

– Check needle bearing



for damage and wear.

» If there is damage or wear:

– Change the needle bearing.

– Check the pivot points of main shaft



and countershaft



for damage and wear.

» If there is damage or wear:

– Change the main shaft and/or countershaft.

– Check the tooth profiles of main shaft



and countershaft



for damage and wear.

» If there is damage or wear:

– Change the main shaft and/or countershaft.

– Check the pivot points of idler gears



for damage and wear.

» If there is damage or wear:

– Change the idler/fixed gear pair.

– Check the shift dogs of idler gears



and fixed gears



for damage and wear.

» If there is damage or wear:

– Change the idler/fixed gear pair.

– Check the tooth faces of idler gears



and fixed gears



for damage and wear.

» If there is damage or wear:

– Change the idler/fixed gear pair.

– Check the tooth profiles of fixed gears



for damage and wear.

» If there is damage or wear:

– Change the idler/fixed gear pair.

– Check fixed gears



for smooth operation in the profile of main shaft



30/ENGINE - WORK ON INDIVIDUAL PARTS

132

» If the fixed gear does not move easily:

– Change the fixed gear or the main shaft.

– Check fixed gears



for smooth operation in the profile of countershaft



» If the fixed gear does not move easily:

– Change the fixed gear or the countershaft.

– Check stop disks



for damage and wear.

» If there is damage or wear:

– Change the stop disk.

– Use new lock rings



in every repair job.

– Assemble the countershaft. (

p. 133)

– Assemble the main shaft. (

p. 132)

19.37

Assembling the main shaft

Info

Use new lock rings in every repair job.

– Oil all parts carefully before assembling.
– Check the transmission. (

p. 131)

300127-01

– Fix the main shaft in the vise with the geared end facing downward.

Guideline

Use soft jaws

– Mount split needle bearing



and put on the fifth-gear idler gear



with the shift dogs facing upward.

– Mount stop disk



and lock ring



– Push on the third/fourth-gear sliding gear



with the small gear wheel pointing downward, and mount lock ring



– Push on stop disk



and split needle bearing



– Put on the sixth-gear idler gear



with the shifting claws facing downward.

– Mount the second-gear fixed gear



with the collar facing downward and mount stop disk



– Finally, check all gear wheels for smooth operation.

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