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KTM (690 Enduro EU, 690 Enduro AUS/UK, 690 Enduro USA). Manual - part 19

30/ASSEMBLING THE ENGINE

149

20.26

Mounting water pump cover

300014-11

– Push on the shaped washer



300013-12

– Attach the water pump wheel



. Mount and tighten screw



Guideline

Screw, water pump wheel

10 Nm
(7.4 lbf ft)

Loctite

243™

Loctite

243™

– Lay on the water pump cover seal



300012-12

– Put on the water pump cover



. Mount and tighten screws.

Guideline

Screw, water pump wheel

10 Nm
(7.4 lbf ft)

Loctite

243™

20.27

Installing thermostat

300010-11

– Position the thermostat



with the gasket.

The drill hole



must face upward.

– Install the thermostat case



with the radiator hose.

– Mount and tighten the screws.

Guideline

Screw, thermostat housing M6

10 Nm
(7.4 lbf ft)

Loctite

243™

20.28

Installing the oil filter

300009-11

– Insert the oil filter



– Lubricate the O-ring of the oil filter cover. Install the oil filter cover



– Mount and tighten the screws.

Guideline

Screw, oil filter cover

6 Nm (4.4 lbf ft)

30/ASSEMBLING THE ENGINE

150

300011-11

– Insert the oil filter



– Lubricate the O-ring of the oil filter cover. Install the oil filter cover



– Mount and tighten the screws.

Guideline

Screw, oil filter cover

6 Nm (4.4 lbf ft)

20.29

Installing gear position sensor

300007-11

– Mount the contact springs



and contact bolt



The contact bolts are mounted with the flat side forward; the pointed sides
face the sensor.

– Position O-ring



302126-11

– Install the gear position sensor



– Position the ground wire



– Mount and tighten the screws.

Guideline

Screw, gear sensor

5 Nm
(3.7 lbf ft)

Loctite

243™

20.30

Installing the spacer

302140-10

– Grease spacer



in area



and O-ring



before mounting.

Long-life grease (

p. 210)

– Position the O-ring in the cut-out of the spacer.

302124-10

– Grease the shaft seal ring.

Long-life grease (

p. 210)

– Slide the spacer with the O-ring onto the countershaft with a twisting motion.

The cut-out with the O-ring faces inward.
The shaft seal ring rests against the spacer along its entire circumference.

30/ASSEMBLING THE ENGINE

151

20.31

Installing oil screens

300152-10

– Push the oil screen with O-rings on to a pin wrench. Push the pin wrench through

the opening into the drill hole of the opposite engine case wall and push the oil
screen as far as possible into the engine case.

300008-10

– Install the oil drain plug with magnet



and a new seal ring and tighten it.

Guideline

Oil drain plug with magnet

M12x1.5

20 Nm
(14.8 lbf ft)

– Install and tighten the plug



with O-rings.

Guideline

Plug, oil screen

M20x1.5

15 Nm
(11.1 lbf ft)

300161-11

– Position the oil screen



with O-rings.

– Install and tighten the plug



with O-rings.

Guideline

Plug, oil screen

M20x1.5

15 Nm
(11.1 lbf ft)

20.32

Installing alternator cover

300005-10

– Apply sealing compound lightly in the area of the cable support sleeve.
– Install the dowel



. Put on the alternator cover seal.

300004-11

– Position the alternator cover.
– Mount and tighten screws



Guideline

Screw in alternator cover

10 Nm (7.4 lbf ft)

– Mount and tighten screw



Guideline

Screw, alternator cover
(chain shaft through-hole)

10 Nm
(7.4 lbf ft)

Loctite

243™

30/ASSEMBLING THE ENGINE

152

300024-11

– Remove special tool



Engine blocking screw (77329010000) (

p. 219)

– Mount and tighten screw



Guideline

Plug, crankshaft location

20 Nm
(14.8 lbf ft)

20.33

Installing starter motor

300001-01

– Grease O-ring. Mount the starter motor.

Long-life grease (

p. 210)

– Mount and tighten screws



Guideline

Screw, starter motor

10 Nm
(7.4 lbf ft)

Loctite

243™

20.34

Installing valve cover

300003-10

– Put the valve cover in place with the seal. Mount and tighten screws



Guideline

Screw, valve cover

10 Nm (7.4 lbf ft)

20.35

Taking engine off universal mounting rack

300144-11

– Remove the screw



or the nut



– Take the engine off the universal mounting rack.

Info

Have an assistant help you or use a crane.

32/CLUTCH

153

21.1

Checking/rectifying the fluid level of the hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

100281-10

– Remove screws



– Remove cover



with membrane



– Check the fluid level.

Fluid level under top level of container

4 mm (0.16 in)

» If the level of the coolant does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

Hydraulic fluid (15) (

p. 209)

– Position the cover with the membrane. Mount and tighten the screws.

35/WATER PUMP, COOLING SYSTEM

154

22.1

Draining coolant

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the

engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

– Remove the engine guard. (

p. 32)

600616-10

– Stand the vehicle upright.
– Place a suitable container under the engine.
– Remove screw



. Remove the radiator cap.

– Completely drain the coolant.
– Fit screw



with a new seal and tighten it.

Guideline

Plug, drain hole of water pump

M10x1

15 Nm
(11.1 lbf ft)

– Install the engine guard. (

p. 32)

22.2

Filling the cooling system

Warning

Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

600618-10

– Stand the motorcycle on its side stand on a horizontal surface.
– Remove radiator cap



600619-10

– Refill the coolant.

Alternative 1

Coolant (

p. 208)

Alternative 2

Coolant (mixed ready to use) (

p. 208)

– Fill the radiator completely with coolant. Mount radiator cap



35/WATER PUMP, COOLING SYSTEM

155

100283-11

– Remove the cap from compensating tank



and add coolant to the level shown in

the figure.

– Mount the cap of the compensating tank.

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 ventila-

tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and run it until the 5th bar of the temperature indicator lights up.
– Switch off the engine and allow it to cool down.
– After the engine has cooled down, check the coolant level in the radiator and in the

compensating tank again and add more coolant if necessary.

22.3

Checking the antifreeze and coolant level

Warning

engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

Condition
Engine is cold.

100283-10

– Stand the motorcycle on its side stand on a horizontal surface.
– Remove the cap of the compensating tank



– Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

– Correct the antifreeze of the coolant.

– Check the coolant level in the compensating tank.

The coolant level must be within the range shown in the figure.

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant (

p. 208)

Alternative 2

Coolant (mixed ready to use) (

p. 208)

– Mount the cap of the compensating tank.

100284-10

– Screw off the radiator cap



– Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

– Correct the antifreeze of the coolant.

– Check the coolant level in the radiator.

The radiator must be completely filled.

» If the coolant level does not meet specifications:

35/WATER PUMP, COOLING SYSTEM

156

– Correct the coolant level and find out the cause of the loss.

Alternative 1

Coolant (

p. 208)

Alternative 2

Coolant (mixed ready to use) (

p. 208)

– Mount the radiator cap.

22.4

Checking the coolant level

Warning

engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-

Condition
Engine is cold.

100283-10

– Stand the motorcycle on its side stand on a horizontal surface.
– Check the coolant level in the compensating tank



The coolant level must be within the range shown in the figure.

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant (

p. 208)

Alternative 2

Coolant (mixed ready to use) (