Content .. 18 19 20 21 ..

KTM (690 Enduro EU, 690 Enduro AUS/UK, 690 Enduro USA). Manual - part 20

38/LUBRICATION SYSTEM

157

23.1

Oil circuit

400500-60

Oil screen

Force pump

Oil filter

Oil pressure regulator valve

Timing chain tensioner

Rocker arm shaft

Transmission

Clutch

Oil jet for piston cooling

Oil filter

Crankshaft

Oil screen

Suction pump

Transmission

23.2

Checking the engine oil level

Info

The engine oil level must be checked when the engine is warm.

Condition
The engine is at operating temperature.
– Stand the motorcycle upright on a horizontal surface.

38/LUBRICATION SYSTEM

158

100210-10

– Check the engine oil level.

Info

After switching off the engine, wait one minute before checking the level.

The engine oil must be between the lower and upper edge of the oil level viewer.

» If the engine oil level is not at the specified level:

– Add the engine oil. (

p. 162)

23.3

Checking the engine oil pressure

Warning

Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning

Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

302039-10

– Remove screw



302040-10

– Position the banjo bolt with the connector and sealing rings. Mount and tighten the

banjo bolt.
Guideline

Banjo bolt

M10x1

8 Nm (5.9 lbf ft)

Oil pressure adapter (77329006000) (

p. 219)

– Connect the pressure tester to the special tool without the T-plate.

Pressure testing tool (61029094000) (

p. 214)

– Check the engine oil level. (

p. 157)

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 let it run warm.
– Check the engine oil pressure.

Engine oil pressure

Coolant temperature: ≥ 70 °C
(≥ 158 °F)
Engine speed: 1,500 rpm

≥ 0.4 bar (≥ 6 psi)

Coolant temperature: ≥ 70 °C
(≥ 158 °F)
Engine speed: 5,000 rpm

≥ 1.5 bar (≥ 22 psi)

» If the specification is not reached:

38/LUBRICATION SYSTEM

159

– Change the oil filter. Check the oil pumps for wear. Check that all oil holes

are clear.

– Switch off the engine.

Warning

Danger of burns Some vehicle components get very hot when the machine
is driven.
– Wear appropriate protective clothing and safety gloves. In case of burns,

rinse immediately with lukewarm water.

– Remove the special tools.
– Mount and tighten screw



Guideline

Screw, unlocking of timing chain ten-
sioner

M10x1

10 Nm (7.4 lbf ft)

– Check the engine oil level. (

p. 157)

23.4

Changing the engine oil and filter, cleaning the oil screens

601022-10

– Drain the engine oil. (

p. 159)

– Remove the oil filter. (

p. 160)

– Clean the oil screens. (

p. 161)

– Install the oil filter. (

p. 160)

– Fill up with engine oil. (

p. 162)

23.5

Draining engine oil

Warning

Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Drain the engine oil only when the engine is warm.

– Remove the engine guard. (

p. 32)

100200-10

– Place a suitable container under the engine.
– Remove the oil drain plug



with the magnet and seal ring.

– Completely drain the engine oil.

38/LUBRICATION SYSTEM

160

100201-01

– Thoroughly clean the oil drain plug with a magnet.
– Refit the oil drain plug with the magnet and seal ring and tighten it.

Guideline

Oil drain plug with magnet

M12x1.5

20 Nm
(14.8 lbf ft)

23.6

Removing the oil filter

Warning

Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

– Place a suitable container under the engine.

100202-10

– Remove screws



. Remove the oil filter cover



with the O-ring.

– Pull oil filter



out of the oil filter housing.

Circlip pliers reverse (51012011000) (

p. 212)

100203-10

– Remove screws



. Remove oil filter



with the O-ring.

– Pull oil filter



out of the oil filter housing.

Circlip pliers reverse (51012011000) (

p. 212)

– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.

23.7

Installing the oil filter

100204-10

– Insert oil filters



and



– Oil the O-rings of the oil filter covers. Mount oil filter covers



and



– Mount and tighten the screws.

Guideline

Screw, oil filter cover

6 Nm (4.4 lbf ft)

38/LUBRICATION SYSTEM

161

23.8

Cleaning the oil screens

Warning

Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

– Place a suitable container under the engine.

100205-10

– Remove screw plug



with oil screen



and the O-rings.

100206-10

– Remove screw plug



with oil screen



and the O-rings.

– Completely drain the remaining engine oil.
– Thoroughly clean the parts and sealing area.

100207-10

– Position oil screen



with the O-rings.

– Mount and tighten screw plug



with the O-ring.

Guideline

Plug, oil screen

M20x1.5

15 Nm
(11.1 lbf ft)

100208-10

– Position oil screen



with the O-rings.

– Mount and tighten screw plug



with the O-ring.

Guideline

Plug, oil screen

M20x1.5

15 Nm
(11.1 lbf ft)

38/LUBRICATION SYSTEM

162

23.9

Filling up with engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

100209-10

– Remove filler plug with O-ring



from the clutch cover and add engine oil.

Engine oil

1.70 l (1.8 qt.)

Engine oil (SAE 10W/60)
(00062010035) (

p. 208)

Alternative engine
oil

Engine oil
(SAE 10W/50)

(

p. 208)

– Refit plug with O-ring



and tighten it.

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 check that it is oil-tight.
– Install the engine guard. (

p. 32)

– Check the engine oil level. (

p. 157)

23.10

Adding engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

100209-10

– Remove the oil filler plug with O-ring



from the clutch cover and fill up with

engine oil.

Engine oil (SAE 10W/60) (00062010035) (

p. 208)

Engine oil (SAE 10W/50) (

p. 208)

Info

For optimal performance of the engine oil, do not mix different types of
engine oil.
If appropriate, change the engine oil.

– Install and tighten the oil filler plug with O-ring



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 check that it is oil-tight.
– Check the engine oil level. (

p. 157)

39/IGNITION SYSTEM

163

24.1

Alternator - checking the stator winding

Condition
The stator is disconnected.
– Reinstall the fuel tank.

600894-10

Stator winding, measurement I - check the resistance

–

Measure the resistance between the specified points.
Stator, connector

EN pin 1 – Stator, connector EN pin 2

Alternator

Resistance of stator winding at:
20 °C (68 °F)

≤ 1 Ω

» If the displayed value is not equal to the setpoint value:

– Replace the stator.

Stator winding, measurement II - check the resistance

–

Measure the resistance between the specified points.
Stator, connector

EN pin 1 – Stator, connector EN pin 3

Alternator

Resistance of stator winding at:
20 °C (68 °F)

≤ 1 Ω

» If the displayed value is not equal to the setpoint value:

– Replace the stator.

600894-10

601014-10

Stator winding - check for a short circuit to ground (terminal 31)

–

Measure the resistance between the specified points.
Stator, connector

EN pin 1 – Measuring point Ground (−)

Resistance

∞ Ω

» If the displayed value is not equal to the setpoint value:

– Replace the stator.

24.2

Checking the spark plug connector

Condition
Spark plug connector cylinder 1 has been removed.

600893-10

–

Measure the resistance between the specified points.
Measuring point 1 – Measuring point 2

Spark plug connector

Resistance at: 20 °C (68 °F)

4.3… 5.7 kΩ

» If the specification is not reached:

– Change the spark plug connector.

39/IGNITION SYSTEM

164

24.3

Ignition coil - checking the secondary winding

Condition
Ignition coil cylinder 1 is disconnected.
Spark plug connector cylinder 1 has been removed.
– Remove the fuel tank.

600739-13

Ignition coil cylinder 1 - check the secondary winding resistance

–

Measure the resistance between the specified points.
Ignition coil pin

2 (+) – Ignition coil pin 3

Ignition coil

Resistance of secondary winding
at: 20 °C (68 °F)

10.4… 15.6 kΩ

» If the displayed value is not equal to the setpoint value:

– Replace the ignition coil.

Content .. 18 19 20 21 ..