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2008 690 SMC EU
KTM 2008 690 SMC EU User Manual
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38/LUBRI
CATION
SYSTE
M
152
22.1
Oil
circuit
400500-60
1
Oil
screen
2
Force
pump
3
Oil
filter
4
Oil
pressure
regulato
r
va
lve
5
Timing
chain
tension
er
6
Rocker
arm
shaft
7
Transmiss
ion
8
Clutch
9
Oil
jet
for
piston
cooling
10
Oil
filter
11
Crankshaft
12
Oil
screen
13
Suction
pump
7
Transmiss
ion
22.2
Checking
the
engine
oil
leve
l
Info
The
engine
oil
level
must
be
checked
when
the
engine
is
warm.
Condition
The
engine
is
at
o
perating
temperature.
–
Stand
the
motorcycle
upright
on
a
horizontal
surface.
153
155
Table of Contents
Table of Contents
4
Means of Representation
7
Important Notes
8
Location of Serial Numbers
9
Chassis Number/Type Label (690 SMC EU, 690 SMC AUS/UK)
9
Chassis Number/Type Label (690 SMC USA)
9
Key Number
9
Engine Number
9
Fork Part Number
10
Shock Absorber Part Number
10
Motorcycle
11
Raising the Motorcycle with the Rear Wheel Stand
11
Taking the Motorcycle off of the Rear Wheel Stand
11
Raising the Motorcycle with the Front Wheel Stand
11
Taking the Motorcycle off of the Front Wheel Stand
11
Raising the Motorcycle with the Work Stand
12
Removing the Motorcycle from the Work Stand
12
Starting
13
Starting the Motorcycle to Make Checks
13
01/Fork, Triple Clamp
14
Adjusting Compression Damping of Fork
14
Adjusting Rebound Damping of Fork
14
Bleeding the Fork Legs
14
Cleaning the Dust Boots of the Fork Legs
15
Removing the Fork Protector
15
Installing the Fork Protector
15
Removing Fork Legs
16
Installing the Fork Legs
17
Servicing the Fork
18
Disassembling the Fork Legs
19
Checking the Fork Legs
22
Assembling the Fork Legs
23
Checking the Steering Head Bearing Play
27
Adjusting the Steering Head Bearing Play
28
02/Handlebar, Instruments
29
Handlebar Position
29
Adjusting Handlebar Position
29
Checking the Play in the Throttle Cable
29
Adjusting the Play in the Throttle Cable
30
04/Shock Absorber, Swingarm
31
Adjusting the High-Speed Compression Damping of the Shock Absorber
31
Adjusting the Low-Speed Compression Damping of the Shock Absorber
31
Adjusting the Rebound Damping of the Shock Absorber
32
Measuring the Unloaded Rear Wheel Sag
32
Checking the Static Sag of the Shock Absorber
32
Checking the Riding Sag of the Shock Absorber
33
Adjusting the Spring Preload of the Shock Absorber
33
Adjusting the Riding Sag
34
Removing the Shock Absorber
34
Installing the Shock Absorber
35
Servicing the Shock Absorber
36
Removing the Spring
37
Dismantling the Damper
37
Disassembling the Piston Rod
38
Checking the Damper
39
Removing the Heim Joint
40
Installing the Heim Joint
41
Assembling the Piston Rod
42
Assembling the Damper
43
Bleeding and Filling the Damper
45
Filling the Damper with Nitrogen
47
Installing the Spring
47
05/Exhaust
49
Removing the Exhaust Manifold
49
Installing Exhaust Manifold
49
Removing the Main Silencer
50
Installing the Main Silencer
51
06/Air Filter
53
Removing the Air Filter
53
Installing the Air Filter
53
Removing the Air Filter Box
53
Installing the Air Filter Box
54
07/Fuel Tank, Seat, Trim
56
Opening Filler Cap
56
Closing Filler Cap
56
Removing the Seat
56
Mounting the Seat
56
Taking off the Side Cover
56
Mounting the Side Cover
57
Checking the Fuel Pressure
57
Changing the Fuel Filter
58
09/Front Wheel
61
Removing Front Wheel
61
Installing the Front Wheel
61
Checking the Tire Air Pressure
62
Checking the Tire Condition
62
Checking the Brake Discs
63
10/Rear Wheel
64
Removing Rear Wheel
64
Installing the Rear Wheel
64
Checking the Chain Tension
65
Adjusting the Chain Tension
65
Adjusting Chain Guide
66
Checking the Chain, Rear Sprocket and Engine Sprocket
66
Cleaning the Chain
67
Checking the Rear Hub Rubber Dampers
68
Checking the Spoke Tension
68
Checking the Rim Run-Out
69
11/Wiring Harness, Battery
70
Removing the Battery
70
Installing the Battery
70
Disconnecting the Battery
70
Connecting the Battery
71
Recharging the Battery
71
Checking the Charging Voltage
72
Changing the Main Fuse
72
Changing Fuses of Individual Power Consumers
73
Adjusting the Engine Characteristic
74
13/Brake System
75
Checking the Front Brake Linings
75
Changing the Front Brake Linings
75
Adjusting the Basic Position of the Hand Brake Lever
76
Checking the Front Brake Fluid Level
76
Adding Front Brake Fluid
77
Changing the Front Brake Fluid
77
Checking the Rear Brake Linings
78
Changing Rear Brake Linings
79
Checking the Free Travel of Foot Brake Lever
80
Adjusting the Basic Position of the Foot Brake Lever
80
Checking Rear Brake Fluid Level
81
Adding Rear Brake Fluid
81
Changing the Rear Brake Fluid
82
14/Light System, Instruments
84
Setting Kilometers or Miles
84
Setting the Clock
84
Combination Instrument - Setting/Resetting TRIP 1
84
Combination Instrument - Setting/Resetting TRIP 2
85
Combination Instrument - Setting the Wheel Circumference
85
Checking the Headlight Setting
86
Adjusting the Headlight Range
86
Removing the Headlight Mask with the Headlight
86
Installing the Headlight Mask with the Headlight
87
Changing the Parking Light Bulb
87
Changing the Headlight Bulb
88
Changing the Flasher Bulb
88
30/Engine
90
Removing the Engine
90
Installing the Engine
92
30/Disassembling the Engine
96
Clamping Engine into Engine Work Stand
96
Draining the Engine Oil
96
Removing Starter Motor
96
Removing Valve Cover
96
Removing the Alternator Cover
97
Removing Spacer
97
Removing Gear Position Sensor
97
Removing Oil Filter
97
Removing Thermostat
98
Setting Engine to Ignition Top Dead Center
98
Removing Water Pump Wheel
98
Removing Clutch Cover
99
Removing Spacer and Spring
99
Removing Spark Plug
99
Removing Timing Chain Tensioner
100
Removing Camshafts
100
Removing Cylinder Head
100
Removing Piston
100
Removing Rotor
101
Removing Timing Chain Rails
101
Removing Timing Chain and Timing Chain Sprocket
102
Removing Crankshaft Position Sensor
102
Removing Clutch Cage
102
Removing Primary Gear
104
Removing Starter Drive
104
Removing Shift Shaft
104
Removing Shift Drum Locating
104
Removing Locking Lever
105
Removing Oil Pumps
105
Removing Left Engine Case
105
Removing Crankshaft and Balancer Shaft
106
Removing Transmission Shafts
106
30/Engine - Work on Individual Parts
108
Work on the Right Section of the Engine Case
108
Work on the Left Section of the Engine Case
109
Work on the Clutch Cover
110
Removing Crankshaft Bearing Inner Ring
111
Removing Balancer Shaft Drive Wheel
111
Changing the Conrod Bearing
111
Checking Crankshaft Run-Out at Bearing Pin
113
Installing Balancer Shaft Drive Wheel
113
Installing Crankshaft Bearing Inner Ring
113
Measuring Axial Clearance of Crankshaft and Balancer Shaft
114
Cylinder - Nikasil Coating
114
Checking/Measuring the Cylinder
115
Checking/Measuring the Piston
115
Checking Piston Ring End Gap
116
Checking Piston/Cylinder Mounting Clearance
117
Checking Oil Pumps for Wear
117
Replacing Autodecompressor
117
Preparing Timing Chain Tensioner for Installation
118
Checking Timing Assembly
119
Removing Rocker Arm
119
Changing Camshaft Bearing
119
Removing Valves
120
Checking Valves
121
Checking Valve Springs
121
Checking Valve Spring Retainer
121
Checking Cylinder Head
121
Installing Valves
122
Installing Rocker Arm
123
Dismantling Antihopping Clutch
123
Checking the Clutch
124
Preassembling Antihopping Clutch
125
Checking Shift Mechanism
126
Preassembling Shift Shaft
126
Disassembling the Main Shaft
127
Dismantling Countershaft
127
Checking the Transmission
128
Assembling the Main Shaft
129
Assembling Countershaft
130
Checking Electric Starter Drive
131
Removing Freewheel
131
Checking Freewheel
132
Installing Freewheel
132
30/Assembling the Engine
134
Installing Transmission Shafts
134
Installing Crankshaft and Balancer Shaft
135
Installing Left Engine Case
135
Installing Oil Pumps
136
Installing Locking Lever
136
Installing Shift Drum Locating
136
Installing Shift Shaft
137
Installing Starter Drive
137
Installing Primary Gear
137
Installing Clutch Cage
138
Installing Crankshaft Position Sensor
139
Installing Timing Chain and Timing Chain Sprocket
139
Installing Timing Chain Rails
140
Installing Rotor
140
Adjusting Crankshaft Position Sensor Distance
140
Setting Engine to Top Dead Center
141
Installing Piston
141
Installing Cylinder Head
142
Installing Camshafts
143
Installing Timing Chain Tensioner
143
Checking Valve Clearance
144
Adjusting Valve Clearance
144
Installing Spark Plug
145
Installing Spacer and Spring
145
Installing Clutch Cover
145
Mounting Water Pump Cover
146
Installing Thermostat
146
Installing the Oil Filter
146
Installing Gear Position Sensor
147
Installing the Spacer
147
Installing Oil Screens
148
Installing Alternator Cover
148
Installing Starter Motor
149
Installing Valve Cover
149
Taking Engine off Universal Mounting Rack
149
32/Clutch
150
Checking/Rectifying the Fluid Level of the Hydraulic Clutch
150
35/Water Pump, Cooling System
151
Draining Coolant
151
Filling the Cooling System
151
Checking the Antifreeze and Coolant Level
152
Checking the Coolant Level
153
38/Lubrication System
154
Oil Circuit
154
Checking the Engine Oil Level
154
Checking the Engine Oil Pressure
155
Changing the Engine Oil and Filter, Cleaning the Oil Screens
156
Draining Engine Oil
156
Removing the Oil Filter
157
Installing the Oil Filter
157
Cleaning the Oil Screens
158
Filling up with Engine Oil
159
Adding Engine Oil
159
39/Ignition System
160
Alternator - Checking the Stator Winding
160
Checking the Spark Plug Connector
160
Ignition Coil - Checking the Secondary Winding
161
41/Throttle Valve Body
162
Checking the Basic Setting of the Motor Drive
162
Adjusting the Basic Setting of the Motor Drive
163
Flashing the EFI Control Unit And/Or the EPT Control Unit
166
Requesting the Enabling Code
167
Coding the EFI Control Unit And/Or EPT Control Unit
168
Technical Data - Engine
170
Capacity - Engine Oil
170
Capacity - Coolant
170
Technical Data - Tolerance, Wear Limits of Engine
171
Technical Data - Engine Tightening Torques
173
Technical Data - Chassis
175
Lighting Equipment
175
Capacity - Fuel
176
Technical Data - Fork
177
Technical Data - Shock Absorber
178
Technical Data - Chassis Tightening Torques
179
Cleaning/Protective Treatment
181
Cleaning the Motorcycle
181
Protective Treatment for Winter Operation
182
Storage
183
Putting into Operation after Storage
183
Service Schedule
184
Wiring Diagram
186
184
186
186
188
188
190
190
192
192
194
194
196
196
198
198
200
200
202
202
204
Substances
206
Auxiliary Substances
208
Special Tools
210
Standards
222
Index
223
5
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KTM 2008 690 SMC EU Specifications
General
Brand
KTM
Model
2008 690 SMC EU
Category
Motorcycle
Language
English
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