690 ENDURO R USA 2009

Transcription

1 SPARE PARTS MANUAL: CHASSIS ART.NO.: 3CF9775I8EN ENGLISH

2 INDEX FRONT FORK, TRIPLE CLAMP FRONT FORK DISASSEMBLED HANDLEBAR, CONTROLS ENGINE GUARD 4x 5x 7x 8x FRAME SIDE / CENTER STAND PRO LEVER LINKING SWING ARM 9x 11x 12x 13x MONOSHOCK EXHAUST SYSTEM AIR FILTER FUEL PUMP 14x 15x 16x 17x 1

3 INDEX TANK, SEAT, COVER MASK, FENDERS DECAL FRONT WHEEL 18x 20x 21x 22x REAR WHEEL BATTERY WIRING HARNESS HAND BRAKE CYLINDER 23x 24x 25x 26x BRAKE CALIPER REAR REAR BRAKE CONTROL BRAKE CALIPER FRONT LIGHTING SYSTEM 27x 28x 29x 30x 2

4 INDEX INSTRUMENTS / LOCK SYSTEM EVAPORATIVE CANISTER SPECIAL TOOLS ACCESSORIES KIT 31x 32x 33x 34x x x x x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 3

5 FRONT FORK, TRIPLE CLAMP E4101 FORK 690 ENDURO R HH COLLAR SCREW M8X25 TX HH COLLAR SCREW M8X30 TX AH SCREW DIN6912-M10X HH COLLAR SCREW M8X40 TX HH COLLAR SCREW M8X25 TX BOT.TRIPLE CLAMP OFFSET FORK TUBE L=237MM TRIPLE CLAMP TOP ADJUST HANDLEBAR CLAMP 28MM HANDLEB.SUPP. D=28MM H=42MM STEER.HEAD SCREW M20X1,5 WS= STE.HEAD SCR. M20X1,5 WS=27 SL TAPERED ROLLER BEARING CPL O-RING SUPPORT W. SEALING LIP STEARING HEAD GASKET TOP STEERING HEAD COVER EJOT PT SCREW K60X20 ALU WS= SPECIAL SCREW M6X12,5 WS= FORK PROTECT. L/S+R/S WHITE CLAMP F. SPEED. CABLE D=6MM HEXAGON NUT DIN0934-M / C * NEW PART X AS REQUIRED 4

6 FRONT FORK DISASSEMBLED S SETTING KNOB + SCREW VENT SCREW M4X O-RING NBR 3,7X1, OUTER TUBE L577 D54/60MM FORK PROTECTION RING DU-BUSH D48XD52X12DDL SUPPORT RING 50 X 57,6 X 1, OIL SEAL RING 48X57,8X9, LOCK WASHER SB DUST CAP D=48 58,4X11, DU-BUSH D47XD49X20DDL S HYDR.STOP L=200 D=31,9 CPL ADJUSTMENT TUBE L= PISTON ROD D=12 L=529 ALU ADJUSTER NEEDLE O-RING 2X1,5 NBR REBOUND SPRING C=4N/MM WASHER 32X42X2, S SPRING D43.2 L N/MM x S SPRING D43.2L N/MM D43.2 x S SPRING D43.2L N/MM D5.25 x INTERM. RING 26,2 X 43 X GUIDING BUSH REBOUND SPRING S SCREW SLEEVE M27X,08 L=100 KPL O-RING 6X1,2 NBR REBOUND SPRING L=32 C= TAP REBOUND SHUTTLE VALVE SPRING C=0, PISTON RING 5X1X PISTON REBOUND SX NUT M6X0,5 REBOUND ADAPTER SLEEVE D23/D PIPE D23/L O-RING NBR 46 X S1 AXLE CLAMP L/S + TUBE CPL S1 AXLE CLAMP R/S + TUBE CPL / C * NEW PART X AS REQUIRED 5

7 FRONT FORK DISASSEMBLED HH COLLAR SCREW M8X25 TX CHECK VALVE NUT M6X0,5 D= SPRING CHECK VALVE D=0, S TAP COMPRESSION CPL PISTON COMPRESSION D=27, O-RING NBR 21X O-RING NBR 24X COPPER WASHER 29,5X33,5X RUBBER CAP D=35MM S1 FORK OIL SAE5 5L S SCREW CAP M51X1,5 CPL SPACER 42X26,5X SPACER 42X26,5X SPACER 42X26,5X2, SPACER 42X26,5X1, T511 SILICONE GREASE F. DUST STRI 1 99 R14015 REPAIR-KIT EXC FRONT FORK / C * NEW PART X AS REQUIRED 6

8 HANDLEBAR, CONTROLS HANDLEBAR D=28 MM RENTHAL THROTTLE GRIP CPL GRIPP SET DUAL COMPOUND THROTTLE CABLE SUPPORT FOR MIRROR LC4 ' REVIEW MIRROR L/S REVIEW MIRROR R/S MASTER CYLINDER MAGURA D= CLAMP MIRROR WITH CLAMP HH COLLAR SCREW M6X20 TX FLAT HEAD SCREW DIN0965-M 4X COVER FOR HYDR. CLUTCH ' RUBBER FOR RESERVOIR ' REP.SET PISTON MAGURA D= PROTECT.CAP FOR LEVER PERCH' SPRING FOR CLUTCH LEVER CLUTCH LEVER LONG CPL LEVER SCREW CPL ' CLUTCH PIPE SM OIL FOR HYD. CLUTCH 75ML CLUTCH SWITCH LIGHT SWITCH L/S START-EMERGENCY STOP SWITCH HANDGUARD L/S+R/S CPL.BLACK / C * NEW PART X AS REQUIRED 7

9 ENGINE GUARD UNDERRIDE PROTECTION CPL CARTER SUPORTER SELF LOCKING NUT DIN0985-M SEAT RUBBER 10 MM RUBBER BUSHING FLAT HEAD SCREW DIN7991-M 8X SPECIAL WASHER ALU 8 X 24 MM SPECIAL SCREW M6X21 WS= / C * NEW PART X AS REQUIRED 8

10 FRAME FRAME "EC08" ORANGE S ENGINE SUPPORT LEFT SIDE S ENGINE SUPPORT RIGHT SIDE AH-COLLAR SCREW M10X24 ISA SPECIAL SCREW M10X115 ISK SCREW COLLAR NUT M10 WS= CHAIN SLID. GUARD SELF LOCKING NUT M10 CU WS= HH COLLAR SCREW M8X20 TX RANGE CHANGE METAL NUT M S FOOTREST BRACKET L/S S FOOTREST BRACKE R/S HH COLLAR SCREW M8X45 TX S FOOT REST BRACKET REAR L/S S FOOT REST BRACKET REAR R/S HEEL PROTECTOR LS HEEL PROTECTOR RS HH COLLAR SCREW M8X16 TX HH COLLAR SCREW M8X12 TX FOOTREST CPL. L/S REAR FOOTREST CPL. R/S REAR BOLT FOR FOOTREST REAR TAB WASHER DIN6799-RS 6, ENGAGE PANEL FOOTREST R/S ENGAGE PANEL FOOTREST L/S FOOTREST L/S+R/S CPL FOOT PEG L/S SILVER FOOT PEG R/S SILVER BOLT FOR FOOT PED FOOTREST SPRING L/S & R/S WASHER DIN0125-A10, PIN DIN0094-3,2X25 STEEL COVER FRAME L/S COVER FRAME R/S RANGE CHANGE METAL NUT M / C * NEW PART X AS REQUIRED 9

11 FRAME SPREAD RIVET CPL. 6,2MM SCREW M5X14 TORX O-RING 8X2 SILICONE ANGLE CONNECTOR LC VENTILATION OIL SEPARATOR FOAM / C * NEW PART X AS REQUIRED 10

12 SIDE / CENTER STAND SIDE STAND ENDURO-R SPRING L=116 MM SCREW F. SIDE STAND M10X31, SPECIAL SCR. SIDE STAND SPRING MAGNET HOLDER HH COLLAR SCREW M6X12 TX SIDE STAND BRACKET HH COLLAR SCREW M8X20 TX SIDE STAND SENSOR CYL.HEAD SCREW DIN84A M4x HOLDER FOR SIDESTAND SWITCH SELF LOCKING NUT DIN0985-M SCREW FOR PLASTIC 50X / C * NEW PART X AS REQUIRED 11

13 PRO LEVER LINKING NEEDLE BUSH HK BUSHING SLEEVE 15 X 20 X STEEL WASHER 15,2X19X0,1 x STEEL WASHER 15,2X19X0,2 x STEEL WASHER 15,2X19X0,3 x SHAFT SEAL RING 25X32X BUCKET FOR SHAFT SEAL RING PULL ROD ANCHOR BOLT NEEDLE BEARING HK SHAFT SEAL RING 18X24X CANTILEVER CPL PULL ROD CPL BOLT CPL. M14X1, S HH COLLAR SCREW M8X16 TX SELF LOCKING NUT M14X1,5 WS= PLASTIC CAP SFL WASHER DIN9021-A 8, LOCK WASHER 8MM / C * NEW PART X AS REQUIRED 12

14 SWING ARM SWING ARM CPL BUCKET FOR SHAFT SEAL RING SHAFT SEAL RING 25X32X BEARING SLEEVE 17X22X38, NEEDLE BEARING HK2212V STOP DISK 22,2X31,7X CHAIN SLIDING GUARD BUSHING F. CHAIN SLIDING PR HH COLLAR SCREW M6X10 TX BRAKE LINE GUIDE SPECIAL SCREW M 5,0X CHAIN GUARD SCREW FOR PLASTIC D=5X HH COLLAR SCREW M6X12 TX HH COLLAR SCREW M6X16 TX CHAIN GUIDE REAR CPL INSERTION NUT F. CHAIN GUIDE HH COLLAR SCREW M6X45 TX HH COLLAR SCREW M6X20 TX SWINGARM BOLT L=246 M12X1, SPECIAL SCREW M12X40 SW HH COLLAR NUT M10X1,25 WS= SCREW M10X1,25X50 WS= CLOSING COVER SWINGARM SM / C * NEW PART X AS REQUIRED 13

15 MONOSHOCK E41 MONOSHOCK 690 ENDURO R S1 SHOCK ABS. UPPER CPL BLEED PLUG R 1/ CYL. SCREW M10X1,25 L= S1 DCC-COMPR.DAMP.CONTROL HS CIRCLIP 49X1, S1 SHOCK ABS BOTTOM CPL. ENDURO 1 21 R15006 REPAIR KIT BEARINGS COUNTERNUT ADJUSTING NUT S SPRING 220MM 75N/MM (61) x S SPRING 220MM 80N/MM (61) x S SPRING 220MM 85N/MM (61) x SPRING RETAINER H=15 D= R15004 REPAIR KIT GASKET S1 SHOCK ABSORBER FLUID 5 LT ' / C * NEW PART X AS REQUIRED 14

16 EXHAUST SYSTEM EXHAUST MANIFOLD SELF LOCKING NUT M 8 CU SPACER BUSH. 8,5X15X7, EXHAUST GASKET LAMBDA SENSOR HEAT SHIELD EXHAUST MAINFOLD SCREW TORX M5X HEAT SHIELD SILENCER GRAPHIT RING 55X50X CLAMP FOR SILENCER 57,4MM SILENCER USA RANGE CHANGE METAL NUT M HH COLLAR SCREW M8X35 TX COLLAR BUSH 8,5X12X23,5X DAMP. COMPONENT SILICONE GREY HH COLLAR SCREW M 8X16 WS= HOLDER SILENCER TOOTH LOCK WASHER DIN6797-J / C * NEW PART X AS REQUIRED 15

17 AIR FILTER FILTER BOX-TOP PART HH COLLAR SCREW M6X12 TX AIRFILTER PAPER 200X HH COLLAR SCREW M6X12 TX RUBBER GROMMET 20X15-M6X10 (1) FILTER BOX WITH INTAKE FLANGE INTAKE FLANGE HOSE CLAMP 50-70MM / C * NEW PART X AS REQUIRED 16

18 FUEL PUMP SEALINGS KIT FILTER KIT FUEL PUMP WITH FLANGE CPL PRESSURE REGULATOR CPL HYDRAULIC CONNECTOR CPL VARIABLE ONE-EAR CLAMP 15,3MM FUEL HOSE WITH CLUTCH O-RING VITON F. PLUG CPC FUEL HOSE WITH CLUTCH HH COLLAR SCREW M5X16 TX CLAMP RSGU 15/ AH SCREW DIN0912-M 4X / C * NEW PART X AS REQUIRED 17

19 TANK, SEAT, COVER FUEL TANK RUBBER BEAR. BOX 12X24 L=24, BEARING BUSHING UP BEARING BUSHING DOWN TANK-RETAINING PLATE R/S TANK-RETAINING PLATE L/S HH COLLAR SCREW M8X16 TX BLIND RIVET 3,3X9,7 GROOVED QUICK RELEASE-SPRING HANGER SEAT LOCK COU.SUNK SCR. AH ISO7380 M6X TANK PLUG KEY BLANK LC4/DUKE/LC8 x SCREW M5X14 TORX CLOSURE FLANGE O-RING 50,00X3,00 VITON SPLASHBACK BUCKET HH COLLAR SCREW M6X10 TX CLAMP F. CABLE SEAT LOCK RUBB.BEAR.BOX 12x24x35 L=24, SEAT SEAT COVER SEAT RUBBER 10 MM BRACKET F. SEAT COLLAR SCREW M6X12 TX SCREW FOR SEAT M6X11,5/ SPOILER LEFT BLACK SPOILER RIGHT BLACK SIDE COVER L/S WHITE SIDE COVER R/S WHITE QUICK RELEASE-NIPPLE RANGE CHANGE METAL NUT M COLLAR BUSHING COLLAR BUSHING HH COLLAR SCREW M6X16 TX / C * NEW PART X AS REQUIRED 18

20 TANK, SEAT, COVER HH COLLAR SCREW M6X12 TX HH COLLAR SCREW M8X30 TX RUBBER GROMMET 20X15-M6X10 (1) 2 ONLY FOR USA / C * NEW PART X AS REQUIRED 19

21 MASK, FENDERS HEAD LIGHT MASK ORANGE EJOT PT SCREW K60X20 ALU WS= FRONT FENDER SPACER BUSHING HH COLLAR SCREW M6X20 TX REFLECTOR YELLOW '99 2 ONLY FOR USA+AUS+UK BRAKE HOSE GUIDE ORANGE MASK RUBBER UFO WP ' REAR FENDER HH COLLAR SCREW M6X12 TX HAND GRIP L/S HAND GRIP R/S COUNTERSUNK SCREW ISA45 M8X NUMBER PLATE CARRIER TOP HH COLLAR SCREW M8X25 TX NUMBER PLATE LO. PART EJOT PT SCREW K60X20 WS= SPECIAL SCREW T60 6X30 WS= COVER RUBBER GROMMET 16X10,8X COLLAR BUSHING 6,1X8,1X14X COLLAR BUSHING LICENCE FITTING HH COLLAR SCREW M6X15 TX WASHER DIN9021-A 6, SELF LOCK. NUT DIN0985-M OVAL HEAD SCREW DIN0966-M 5X WASHER 6MM WASHER DIN0125-A 5, SELF LOCKING NUT DIN0985-M REFLECTOR RED LC4 ' BRACKET FOR REFLECTOR BRACKET SIDE REFLECTOR SIDE REFLECTOR RED REAR 2 ONLY FOR USA / C * NEW PART X AS REQUIRED 20

22 DECAL DECAL SET 690 ENDURO R / C * NEW PART X AS REQUIRED 21

23 FRONT WHEEL FRONT WHEEL CPL. 1,85X21'' FRONT HUB CPL BEA.SPACERTUBE 35X2 L=79, GR.BALL BEAR.6906 DDU2CG23S6NM FRONT WHEEL REP. KIT SHAFT SEAL RING 35X47X7 TC SPACER BUSHING F. FR. WHEEL PLUG FOR RIM RIM 1,85X21" DID BLACK SPOKE M4,5X226-18'' INOX SPOKE NIPPLE M4,5X0,75 8X HOSE 21" RIM BAND FRONT 2MM PLUG BUSHING WS= WHEEL SPIN.FR. D=26 M24x1, AUXILIARY SCREW FRONT SPINDLE SCREW M24X1,5 WS= FRONT BRAKE DISC D= SPECIAL SCREW M6X13 WS= / C * NEW PART X AS REQUIRED 22

24 REAR WHEEL REAR WHEEL CPL. 2,50X18'' REAR HUB CPL BEARING SPACER TUBE L=106MM GR.BALL BEAR RSHC3HMTF CIRCLIP DIN X SHAFT SEAL RING 30X52X SPACER BUSH. REAR WHEEL R/S SPACER RING RIM 2,50X18" DID BLACK SPOKE M5X217-17G 18" INOX SPOKE M5X207-27G 18" INOX SPOKE NIPPLE M5-TA 8X21MM HOSE 110/100C RIM BAND REAR 2MM PLUG FOR RIM SPROCKET STEALTH 42T 07 x SPROCKET 45T 08 x S COUNTER-SUNK SCREW ISA45 M8X SELF LOCKING NUT M SPROCKET SUPPORT CPL SPACER BUSH. SPROCKET SUPP NILOS RING 6006AV BALL BEARING 6006 DDU2CG23S6NM SPACER BUSH. SPR. SUPP. IN RUBBER DAMPING BLOCK ' BRAKE DISC REAR D=240MM SPECIAL SCREW M6X13 WS= WHEEL SPINDLE M25X1,5 L=275MM CHAIN TENSIONER R/S LC COLLAR NUT WH. SPINDLE REAR CHAIN X-RING RIVET LINK RIVET LINK FOR / C * NEW PART X AS REQUIRED 23

25 BATTERY STARTER-CABLE L=570MM BATTERY-CABLE L=170MM GROUND CABLE L=420MM RETAINING PLATE BATTERY BATTERY 12V 8,6AH GROUND CABLE D=6MM L=140MM ' STARTER RELAY 12V ' FUSE 30 A BATTERY BRACKET RELAY CM1A-R-12V-H HH COLLAR SCREW M5X12 TX HOLDER F.ELECTRIC RUBBER GROMMET 20X15-M6X10 (1) HH COLLAR SCREW M6X8 TX AH OVAL SCREW ISO 7380 M 6X AH SCREW DIN 912 M 5X POSITIVE POLE COVER HH COLLAR SCREW M6X16 TX HH COLLAR SCREW M6X10 TX HEXAGON NUT DIN0934-M HH COLLAR SCREW M6X13 TX RETAINING PLATE STARTER CABLE CONTACT WASHER M6 VSV-K / C * NEW PART X AS REQUIRED 24

26 WIRING HARNESS MAIN WIRING HARNESS BH SPARE CONNECTOR BH 6-PINS FUSE 10A 07 x FUSE 15A 07 x RUBBER CASING FOR FUSE BOX CABLE FOR HEAD LIGHT SCREW FOR PLASTIC 50X SELF LOCK. NUT DIN0985-M DC HORN CPL CABLE TIE 100/2,5MM BLACK x CABLE TIE 200/3,6MM BLACK x CABLE TIE 300/4,8MM BLACK x RUBBER CABLE TIE 75MM 03 x FLASHER UNIT WIRING HOLDER DIODE S3H VOLTAGE REGULATOR HH COLLAR SCREW M6X25 TX RANGE CHANGE METAL NUT M MAP-SELECT-SWITCH RUBBER HOLDER F. MAP-SEL-SWIT / C * NEW PART X AS REQUIRED 25

27 HAND BRAKE CYLINDER HAND BRAKE CYLINDER HAND BRAKE CYL. COVER CPL REP.SET PISTON EXC CLAMP F. MIRROR CPL BRAKE LIGHT SWITCH FRONT LEVER SCREW CPL HAND BRAKE LEVER LOOSE BREM' ADJUSTING SCREW CPL PROTECTION CAP BREMBO' CLAMP 06 x CABLE F. BRAKELIGHT SWITCH FR BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 26

28 BRAKE CALIPER REAR BRAKE CALIPER - WITHOUT PADS BRAKE CALIPER SUPPORT REAR RETAINING SPRING SET CUP SET SHORT BLEEDER SCREW WITH CAP BRAKE PISTON 32MM REPAIR KIT SEALING RINGS 32MM BRAKE PAD SET REAR SBS-S-40GF BOLT SET HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X BRAKE HOSE REAR 805MM / C * NEW PART X AS REQUIRED 27

29 REAR BRAKE CONTROL 1* FOOT BR. LEVER + STEP PLATE STEP PLATE FOOT BRAKE LEVER SCREW TORX M5X * SLIDE BEARING FOOT BRAKE LEVER 2 6* SPECIAL SCREW M10 LH PRECOTE RETURN SPRING FOR BRAKE LEVER HH SCREW DIN933 M5x HEXAGON NUT DIN0934-M PUSH ROD S HH COLLAR SCREW M6X20 TX FOOT BRAKE CYLINDER 13MM STOP NUT M6 DIN6926 A HH COLLAR SCREW M6X25 TX YDNAC CLAMP (9MM) HOSE FOR RESERVOIR 6X1,5 x BRAKE FLUID RESERVOIR ' COLLAR SCREW M6X12 TX COPPER GASKET DIN X14X BRAKE HOSE REAR 805MM BRAKE LIGHT SWITCH REAR ANGLE PIECE REPAIR KIT PISTON 13MM HOLLOW SCREW BLACK M10X1X BRACKET FOR BRAKE HOSE HH COLLAR SCREW M5X16 TX RUBBER SLEEVE BRAKE FLUID DOT5.1 0,25L / C * NEW PART X AS REQUIRED 28

30 BRAKE CALIPER FRONT BRAKE CALIPER FRONT L/S RETAINING PLATE SET FRONT CUP SET SHORT BLEEDER SCREW WITH CAP BRAKE PADS TOSHIBA TT 2172 HHA BOLT SET L/S BRAKE HOSE FRONT 1265MM HOLLOW SCREW BLACK M10X1X COPPER GASKET DIN X14X BRAKE PISTONS 30/32MM REP.KIT SEALING RINGS 30/32MM BRAKE CALIPER SUPPORT FR. L/S WASHER DIN0125-A 8, S HH COLLAR SCREW M8X35 TX / C * NEW PART X AS REQUIRED 29

31 LIGHTING SYSTEM HEAD LIGHT CPL. EXC-EU BILUX-BULB 12V 35/35W BA20D RUBBER CAP FOR HEAD LIGHT SCREW FOR PLASTIC K50X18 T CABLE FOR HEAD LIGHT FLASHER CPL.FRONT L/S REAR R/S FLASHER CPL.FRONT R/S REAR L/S FLASHER LENS L/S R/S TRANSP BULB 12V ORANGE (RY10W) WASHER 18x10,5x1, LOCK WASHER DIN6797-J10,5 ZI HH COLLAR NUT M10X1,25 WS= SHEET MET. SCR. DIN7981 3,5X BULB 12V 21/5W (BAY15S)REINFO REAR LIGHT CPL. EXC REAR LIGHT LENS EGS' WIRING HARNESS REAR ' BULB 12V 5W (W2,1X9,5D) PHIL WASHER DIN9021-A 6, SELF LOCK. NUT DIN0985-M WIRING HARNESS FLASHER REAR / C * NEW PART X AS REQUIRED 30

32 INSTRUMENTS / LOCK SYSTEM SPEEDOMETER SPEEDOMETER SENSOR RUBBER CABLE TIE 45MM CYL.HEAD SCREW DIN0084-M 4X8 A RUBBER GROMMET 16X10,8X SPEEDOMETER BRACKET WASHER DIN9021-A 5, SCREW FOR PLASTIC 50X RUBBER SLEEVE D=8MM OPEN COLLAR BUSHING 6,1X8,1X14X HH COLLAR SCREW M6X15 TX PLUG CAP KV LOCK SET IGNITION LOCK TANK PLUG KEY BLANK LC4/DUKE/LC8 x SPECIAL SCREW M6X13 WS= O-RING 1,78x10,82x14, / C * NEW PART X AS REQUIRED 31

33 EVAPORATIVE CANISTER EVAPORATIVE CANISTER FITTING PIECE NQV2 NW VALVE FOR CARBON CANISTER YDNAC CLAMP (9MM) VACUUM CONECTION M6/0,5MM HOSE EPA D=6/10 L=2000MM x HOSE EPA D=4/8 L=2000MM x REDUCTION CONNECTION GRS RANGE CHANGE METAL NUT M RET.PLATE EVAPORATIVE CANISTER HH COLLAR SCREW M6X12 TX CLAMP RSGU 18/ RETAINING PLATE VALVE EC METAMOLL 90X45X3MM YDNAC-CLAMP FUEL HOSE (8MM) COLLAR SCREW M5X12 ISA PVC-CLAMP 7,9 MM HEYCO CYL.HEAD SCREW DIN0084-M 4X8 A / C * NEW PART X AS REQUIRED 32

34 SPECIAL TOOLS VEHICLE STAND BRACKET FOR ASSEMBLING RACK ATTACHMENT SHUNTING JACK CPL STOP RUBBER M HEXAGON NUT DIN0934-M / C * NEW PART X AS REQUIRED 33

35 ACCESSORIES KIT BAG FOR INSTRUCTION MANUAL COUNTERSUNK SCREW ISA45 M8X WASHER DIN9021-A 6, HH COLLAR SCREW M6X15 TX HH COLLAR SCREW M8X12 TX HH COLLAR SCREW M8X16 TX WASHER DIN0125-A 5, OVAL HEAD SCREW DIN0966-M 5X SELF LOCKING NUT DIN0985-M SELF LOCK. NUT DIN0985-M DOCUMENTS BAG KTM BALLPOINT ORANGE CUSTOMER WELCOME LETTER WASHER 6MM RUBBER L=145MM SUPPORT FOR MIRROR LC4 ' REFLECTOR RED LC4 ' BRACKET FOR REFLECTOR LICENCE FITTING REVIEW MIRROR L/S REVIEW MIRROR R/S HEEL PROTECTOR LS HEEL PROTECTOR RS FOOTREST L/S+R/S CPL S FOOT REST SUPPORT REAR L/S S FOOT REST SUPPORT REAR R/S UNDERRIDE PROTECTION CPL HAND GRIP L/S HAND GRIP R/S EN OWN.MANUAL 690 ENDURO-R CF9775I8EN SPC CHASSIS 690 ENDURO R CM088506IEN SPC ENGINE 690 ENDURO USA TOOL SET GRIP ORANGE B&F WRENCH SW=17/21/27/32 B&F T-WRENCH WS=6/8/10 TX=45 B&F / C * NEW PART X AS REQUIRED 34

36 ACCESSORIES KIT SCREW DRIVER L=105MM WRENCH WS=13 B&F + OPENER SPARK PLUG WRENCH / C * NEW PART X AS REQUIRED 35

37 690 LC4 ENDURO USA 2010 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM088506JEN ENGLISH

38 INDEX 690 LC4 ENDURO USA 2010 DIAGNOSTIC TOOL ENGINE CASE CLUTCH COVER BALANCER SHAFT 3x 4x 6x 7x CYLINDER CRANKSHAFT, PISTON SECONDARY AIR SYSTEM SAS CLUTCH 8x 9x 10x 11x TRANSMISSION I - MAIN SHAFT TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM WATER PUMP 12x 13x 14x 15x 1

39 INDEX 690 LC4 ENDURO USA 2010 COOLING SYSTEM VALVE DRIVE TIMING DRIVE CYLINDER HEAD 16x 17x 19x 20x LUBRICATING SYSTEM IGNITION SYSTEM ELECTRIC STARTER THROTTLE BODY 21x 22x 23x 24x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 2

40 DIAGNOSTIC TOOL 690 LC4 ENDURO USA DIAGNOSTIC TOOL HUSABERG/KTM DIAGNOSTIC TOOL KTM BREAKOUT-BOX KPL BREAKOUT-BOX TEMPLATE LC8 / RC TEMPLATE LC TEMPLATE HUSABERG ADAPTER LC4 EFI ADAPTER LC4 EPT/HUSABERG EFI ADAPTER LC DIAGNOSTIC HASP DONGLE XC POWERSUPPLY 220V/12V FOR AVL EXTENSION CABLE DIAGNOSTIC CABLE HUSABERG DIAGNOSTIC CABLE KTM CASE FOR DIAGNOSTIC-TOOL BASIC SOFTWARE DVD KTM / C * NEW PART X AS REQUIRED 3

41 ENGINE CASE 690 LC4 ENDURO USA ENGINE CASE CPL.W.BEAR. LC O-RING 6,00X1, PLUG DIN0910-M 10X COPPER GASKET DIN X14X DOWEL 6X8X11, OIL JET 50 M6X0,75 WS WASHER DIN9021-A 5, FLAT HEAD SCREW ISO 7380 M5X VENTILATION CONNECTOR M16X1, O-RING 17,17X1,78 GLO PLUG M20X1,5 WS= OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, CASE BUSH 2 16* AH SCREW DIN7984 M5X10 A COVER LOCK PIECE BUSHING PIN O-RING 18,00X2,00 NBR BUSHING PIN DOWEL 17 X 13 X DOWEL 21X MEMBRANE STOP SHEET MEMBRANE CYLIND.SCREW M3X8 ISO SS SEAL RING CU DIN7603-8X12X HH COLLAR SCREW M8X16 TX HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X70 TX JET CLAMP STD DN OIL HOSE BLEEDER FLANGE CABLE TIE 200/3,6MM BLACK x HH COLLAR SCREW M6X40 TX / C * NEW PART X AS REQUIRED 4

42 ENGINE CASE 690 LC4 ENDURO USA CHAIN GUARD CPL HH COLLAR SCREW M8X35 TX GASKET SET LC / C * NEW PART X AS REQUIRED 5

43 CLUTCH COVER 690 LC4 ENDURO USA CLUTCH COVER CPL PLUG CPL. M24X DOWEL 9,8 X 7 X OIL LEVEL GLASS G 1777 Y CIRCLIP OIL LEVEL GLASS SHAFT SEAL RING 17X28X7B VITON CLUTCH CASE GASKET SCREW PLUG HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X30 TX O-RING 19,00X3,00 NBR / C * NEW PART X AS REQUIRED 6

44 BALANCER SHAFT 690 LC4 ENDURO USA BALANCER SHAFT CPL THRUST WASHER DIN X32X,1 x THRUST WASHERDIN X32X,15 x THRUST WASHER DIN X32X,2 x THRUST WASHER DIN X32X,3 x BALL BEARING 62/22 C / C * NEW PART X AS REQUIRED 7

45 CYLINDER 690 LC4 ENDURO USA CYLINDER AND PISTON HH COLLAR SCREW M6X25 TX CYLINDER BASE GASKET GROOVED PIN DIN1474 5X / C * NEW PART X AS REQUIRED 8

46 CRANKSHAFT, PISTON 690 LC4 ENDURO USA CRANKSHAFT CPL WOODRUFF KEY DIN6888 4X5X CYL.ROLLER BEARING NJ207 ECPC SHIM WASHER 36X48X0,10 x SHIM WASHER 36X48X0,15 x SHIM WASHER 36X48X0,20 STEEL x SHIM WASHER 36X48X0,30 x PRIMARY GEAR 36 T NUT FOR PRIMARY GEAR DRIVE WHEEL BALANCER SHAFT TENSION PIN ISO X TIMING PULLEY WOODRUFF KEY DIN6888-3X5X WOODRUFF KEY 5X6,5 HARDED CIRCLIP DIN X1,5 NIRO LOCK WASHER VSK HEXAGON NUT DIN0936-M18X1,5 R SHAFT SEAL R.35X50X7B VITON CONNECT. ROD REPAIR SET LC PISTON PIN EB 22/72 d22x CIRCLIP I PISTON CPL. I x II PISTON CPL. II x PISTONRING SET LC / C * NEW PART X AS REQUIRED 9

47 SECONDARY AIR SYSTEM SAS 690 LC4 ENDURO USA SLS-VALVE CLAMP STD DN PREFORMED HOSE SAS AIR BOX PRE. HOSE SAS BREATHER-COVER SCREW FOR PLASTIC K50X18 T / C * NEW PART X AS REQUIRED 10

48 CLUTCH 690 LC4 ENDURO USA HH COLLAR SCREW M5X25 ISA SPRING RING CLUTCHSPRING 3,0X33, PRESSURE CAP HEXAGON NUT M20X1,5 7MM LOCK WASHER INNER CLUTCH HUB MOVABLE CLUTCH RELEASE SPRING INNER CLUTCH HUB FIXED STEPPED WASHER HALF-WASHER OUTER CLUTCH HUB CPL OIL PUMP DRIVE WHEEL NEEDLE BEARING K26X30X22ZW.KSE WASHER 26X40X GROOV.BALL BEAR RSR C PRESSURE BOLT PUSH ROD GASKET FOR SLAVE CYLINDER O-RING 30,00X1,50 NBR BLEEDER SCREW WITH CAP OUTPUT CYL. WITH BLEEDER SCREW HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X20 TX STEEL DISK 1,5 MM LC LINING DISK 2,7MM FCC RONDELLA ANTIVIBRAZIONE SET LINING DISC CUT OUT STEEL DISK 1,5MM NITRIDED HOLDING SCREW GMB-M5X / C * NEW PART X AS REQUIRED 11

49 TRANSMISSION I - MAIN SHAFT 690 LC4 ENDURO USA BALL BEARING 58/28 C4 N MAIN SHAFT NEEDLE BEAR. K 22X26X13 TN STOP DISK 22,7 X 32 X 1, STOP-V-RING AV IDLER GEAR 5.G /4TH GEAR MAINSHAFT IDLER 6. GEAR SOLID GEAR 2.G SHIM 20X32X BALL BEARING 6004 TNH C GUIDE BUSHING BEARING BUSH / C * NEW PART X AS REQUIRED 12

50 TRANSMISSION II - COUNTERSHAFT 690 LC4 ENDURO USA COUNTER SHAFT SLIDING GEAR 6TH G CIRCLIP SW STOP DISK 22,7 X 32 X 1, IDLER 2. GEAR NEEDLE BEAR. K 22X26X13 TN CYL.ROLLER BEARING NJ205 C SHAFT SEAL R. 32X47X7BSL VITON O-RING 25,12X1,78 NBR SPACER BUSHING 12MM ENGINE SPROCKET 15 T DAMPED x ENGINE SPROCKET 16 T DAMPED x ENGINE SPROCKET 17 T DAMPED x LOCK WASHER SPROCKET NUT LC BALL BEARING 6004 C4 N SHIM 20X32X IDLER GEAR 1ST GEAR NEEDLE BEARING K22X26X13H STOP DISK 22,2X31,7X TH GEAR COUNTERSHAFT IDLER GEAR 3.G IDLER GEAR 4.G CIRCLIP DIN471 20X1, BEARING BUSH / C * NEW PART X AS REQUIRED 13

51 SHIFTING MECHANISM 690 LC4 ENDURO USA SHIFT FORK F. SLIDINGGEAR SHIFT FORK F. SLIDINGG. 3/ SHIFT FORK F. SLIDINGGEAR NEEDLE ROLLER DIN5402 6X14, SHIFTRAIL SHIFT SHAFT CPL TENSIONING SPRING 0,8MM SPRING GUIDE RETURN SPRING 2,2MM ' STOP DISK 14X30X1,5 STEEL NEEDLE BEAR.HK X20X SHAFT SEAL RING 14X24X6B VITON SHIFT LEVER CPL SHIFTING LEVER SPRING BOLT 6X25 FOR SHIFT LEVER STEEL WASHER 6,4X17X PAIR OF WASHERS M 6 NORDLOCK SPECIAL SCREW M6X16 WS= HH COLLAR SCREW M6X20 TX LOCKING LEVER CPL SLEEVE FOR LOCKING LEVER ARRESTING LEVER SPRING AH SCREW DIN6912 M6X SHIFT DRUM LOCATING CPL % BALL BRG 6805 C4 NTN JAPAN SHIFT ROLLER CPL NEEDLE BEAR HK X42X CONTACT SPRING CONTACT BOLT O-RING 27,5X2,5 NBR GEAR-POSITION SENSOR HH COLLAR SCREW M5X16 TX SPACER SPRING FOR OPERATING SHAFT / C * NEW PART X AS REQUIRED 14

52 WATER PUMP 690 LC4 ENDURO USA THERMOSTAT SUPPORTING SLEEVE HH COLLAR SCREW M6X20 TX THERMOSTATCOVER HH COLLAR SCREW M6X30 TX WATERPUMP COVER WATER PUMP COVER GASKET HH COLLAR SCREW M6X15 TX WATER PUMP ROTOR FORM WASHER 16X1 NIRO SHAFT SEAL RING. 12X30X7 VITON SHAFT SEAL RING 12X30X7 PTFE GROOVED PIN DIN1474 5X / C * NEW PART X AS REQUIRED 15

53 COOLING SYSTEM 690 LC4 ENDURO USA RADIATOR HOSE 6X10 EPDM 03 x PLUG F. EXPANSION TANK YDNAC-CLAMP MM ANGLE CONNECTION EXPANS. TANK RUBBER GROMMET 6X9X13MM COLLAR SCREW M6X12 TX O-RING 17X1,5 NB THERMOSWITCH LC8 102DG ' SCREW OIL TANK FIXING RUBBER SLEEVE D=12MM RADIATOR CAP 1,4 BAR HH COLLAR SCREW M6X12 TX RADIATOR HOSE VARIABLE ONE-EAR CLAMP 33,1MM CLAMP STD DN RADIATOR HOSE FAN L/S SPECIAL SCREW T60 6X30 WS= HH COLLAR SCREW M6X10 TX RUBBER GROMMET 20X15-M6X10 (1) SELF LOCK. NUT DIN0985-M RADIATOR PROTECTION HH COLLAR SCREW M6X12 TX HH COLLAR SCREW M6X10 TX ALU-GASKET 6X10X EXPANSION TANK CPL EJOT PT SCREW K60X20 WS= RETAINING PLATE RADIATOR RANGE CHANGE METAL NUT M FAN COWL COLLAR BUSHING / C * NEW PART X AS REQUIRED 16

54 VALVE DRIVE 690 LC4 ENDURO USA INTAKE VALVE EXHAUST VALVE VALVE SPRING HOLDER VALVE-STEM SEALING RACING VALVE SPRING KIT VALVE SPRING RETAINER VALVE COLLET MK SHIM D=10/1,85 03 x SHIM D=10/1,90 03 x SHIM D=10/1,95 03 x SHIM D=10/2,00 03 x SHIM D=10/2,05 03 x SHIM D=10/2,10 03 x SHIM D=10/2,15 03 x SHIM D=10/2,20 03 x SHIM D=10/2,25 03 x SHIM D=10/2,30 03 x SHIM D=10/2,35 03 x SHIM D=10/2,40 03 x SHIM D=10/2,45 03 x SHIM D=10/2,50 03 x SHIM D=10/2,55 03 x SHIM D=10/2,60 03 x SHIM D=10/2,65 03 x SHIM D=10/2,70 03 x SHIM D=10/2,75 03 x SHIM D=10/2,80 03 x SHIM D=10/2,85 03 x SHIM D=10/2,90 03 x SHIM D=10/2,95 03 x SHIM D=10/3,00 03 x SHIM D=10/3,05 03 x SHIM D=10/3,10 03 x SHIM D=10/3,15 03 x SHIM D=10/3,20 03 x / C * NEW PART X AS REQUIRED 17

55 VALVE DRIVE 690 LC4 ENDURO USA ROCKER ARM EXHAUST CPL ROCKER ARM INTAKE CPL ROCKER ARM SHAFT AH SCREW DIN912 M6x AH SCREW DIN0912 M 6X VALVE KIT x / C * NEW PART X AS REQUIRED 18

56 TIMING DRIVE 690 LC4 ENDURO USA NEEDLE SLEEVE HK1814RS18/24/ NEEDLE SLEEVE HK4012B40X47X CAMSHAFT CAMSHAFT HOLDER HH COLLAR SCREW M6X12 TX AUTO DECOMPRESSION HALF MOON RING H6-BLS AUTO DECO WEIGHT SPRING FOR AUTO DECOMPR DECO SCREW TIMING CHAIN 104 LINKS HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH SCREW PLUG CHAIN ADJ CU SEAL-RING 20X27X CHAIN ADJUSTER HYD TENSIONER RAIL SECURING GUIDE GUIDE RAIL SUPPORTING SLEEVE S HH COLLAR SCREW M6X30 TX TIMING PULLEY CIRCLIP DIN X1,5 NIRO O-RING 18,00X2,00 NBR / C * NEW PART X AS REQUIRED 19

57 CYLINDER HEAD 690 LC4 ENDURO USA CYLINDER HEAD CPL CYLINDER HEAD GASKET GROOVED PIN DIN1474 5X STUD DIN0835-M 8X VALVE GIUDE EXHAUST VALVE GIUDE INTAKE SHIM 10,2X19X1,5MM CYLINDERHEAD SCREW M10X168WS TEMPERATURE SENSOR WATER O-RING 10,00X2,00 SILCONE DOWEL 9,8 X 7 X SCREW PLUG VALVE COVER GASKET VALVE COVER BREATHER COVER * AH SCREW DIN7984 M5X10 A O-RING 15,00X1,50 VITON VALVE COVER SCREW DECOUPLING ELEMENT INTAKE BOOT HOSE CLAMP GEMI 70MM VACUUM CONECTION M6/0,5MM HH COLLAR SCREW M6X25 TX SLS-VALVE PRE.HOSE OIL SEPARATOR FOAM CLAMP STD DN CLAMP 21X12 STD-DES / C * NEW PART X AS REQUIRED 20

58 LUBRICATING SYSTEM 690 LC4 ENDURO USA TAB WASHER DIN6799-RS 6, STOP DISK 8,1 X 15 X 0, OIL PUMP GEAR 20-T AH SCREW DIN7984 M5X10 A OIL PUMP SHAFT NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, OILPUMP ROTOR 15MM G OILPUMP ROTOR CPL. 10MM G-73R HH COLLAR SCREW M5X16 TX OILFILTER CAP O-RING 39,34X2,62 NBR 70 SH OIL FILTER SHORT WITH GASKET OIL FILTER LONG VALVE PISTON D=10MM OIL PRES.SPRING 5 BAR RED CU-SEAL RING DIN X18X1, PLUG DIN0908-M12X1, O-RING 12,5X1,5 VITON V OIL SCREEN 15X83MM O-RING 17,17X1,78 GLO PLUG M20X1,5 WS= OIL PUMP COVER OIL PUMP SHAFT OIL PUMP DRIVE WHEEL / C * NEW PART X AS REQUIRED 21

59 IGNITION SYSTEM 690 LC4 ENDURO USA IGNITION COVER DOWEL 9,8 X 7 X CABLE SUPPORT GENERATOR O-RING 24X2,5 VITON SCREW PLUG M24X1,5 PA IGNITI.COVER GASKET STATOR FLYWHEEL HH COLLAR SCREW M5X16 TX IGNITIONCOIL SPARK PLUG CONNECT SPARK PLUG M12X1,25 LKAR8AI HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X30 TX PULSER COIL HH COLLAR SCREW M6X16 TX / C * NEW PART X AS REQUIRED 22

60 ELECTRIC STARTER 690 LC4 ENDURO USA E-STARTER ENGINE CPL O-RING 33,5X3 VITON HH COLLAR SCREW M6X20 TX NEEDLE SLEEVE HK X23X INTERMEDIATE GEAR NEEDLE BEARING K17X21X FREE WHEEL TORQUE LIMITER STOP DISK 17,2X25X CIRCLIP DIN X CIRCLIP DIN0472 J FREEWHEEL GEAR NEEDLE BEAR. K 26X30X STOP DISK 17,2X22X CIRCLIP DIN X / C * NEW PART X AS REQUIRED 23

61 THROTTLE BODY 690 LC4 ENDURO USA THROTTLE BODY MAP SENSOR CPL FUEL RAIL ASSY SET FUEL INJECTOR ASSY SET TPS SENSOR CPL APS UNIT CPL PACKING CONNECTOR JOINT O-RING WASHER SCREW TORX O-RING PLATE, STAY SCREW WASHER O-RING SCREW SHOULDER SCREW SHOULDER SEAL RING RUBBER SUPP. PRESSURE SENS PRESSURE SENSOR HOSE 3,2X8,5 PER METER x ROLLOVER SENSOR SHIM 4,3X15X1,25MM GALVANIZED AH SCREW DIN0912-M 4X AMBIENT-AIR TEMPERATURE SENSOR SCREW FOR PLASTIC K50X12 T TIMING CHARGER EPT TIMING CHARGER EFI / C * NEW PART X AS REQUIRED 24