KTM 2008 690 SMC EU - Page 172

KTM 2008 690 SMC EU

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TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 170

Main shaft axial clearance 0.10… 0.40 mm (0.0039… 0.0157 in)

Transmission shaft run-out ≤ 0.025 mm (≤ 0.00098 in)

Shift shaft - play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in)

Fuel pressure

Under every load condition 3.3… 3.7 bar (48… 54 psi)

Table of Contents

Table of Contents4
Means of Representation7
Important Notes8
Location of Serial Numbers9
- Chassis Number/Type Label (690 SMC EU, 690 SMC AUS/UK)9
- Chassis Number/Type Label (690 SMC USA)9
- Key Number9
- Engine Number9
- Fork Part Number10
- Shock Absorber Part Number10
Motorcycle11
- Raising the Motorcycle with the Rear Wheel Stand11
- Taking the Motorcycle off of the Rear Wheel Stand11
- Raising the Motorcycle with the Front Wheel Stand11
- Taking the Motorcycle off of the Front Wheel Stand11
- Raising the Motorcycle with the Work Stand12
- Removing the Motorcycle from the Work Stand12
- Starting13
- Starting the Motorcycle to Make Checks13
01/Fork, Triple Clamp14
- Adjusting Compression Damping of Fork14
- Adjusting Rebound Damping of Fork14
- Bleeding the Fork Legs14
- Cleaning the Dust Boots of the Fork Legs15
- Removing the Fork Protector15
- Installing the Fork Protector15
- Removing Fork Legs16
- Installing the Fork Legs17
- Servicing the Fork18
- Disassembling the Fork Legs19
- Checking the Fork Legs22
- Assembling the Fork Legs23
- Checking the Steering Head Bearing Play27
- Adjusting the Steering Head Bearing Play28
02/Handlebar, Instruments29
- Handlebar Position29
- Adjusting Handlebar Position29
- Checking the Play in the Throttle Cable29
- Adjusting the Play in the Throttle Cable30
04/Shock Absorber, Swingarm31
- Adjusting the High-Speed Compression Damping of the Shock Absorber31
- Adjusting the Low-Speed Compression Damping of the Shock Absorber31
- Adjusting the Rebound Damping of the Shock Absorber32
- Measuring the Unloaded Rear Wheel Sag32
- Checking the Static Sag of the Shock Absorber32
- Checking the Riding Sag of the Shock Absorber33
- Adjusting the Spring Preload of the Shock Absorber33
- Adjusting the Riding Sag34
- Removing the Shock Absorber34
- Installing the Shock Absorber35
- Servicing the Shock Absorber36
- Removing the Spring37
- Dismantling the Damper37
- Disassembling the Piston Rod38
- Checking the Damper39
- Removing the Heim Joint40
- Installing the Heim Joint41
- Assembling the Piston Rod42
- Assembling the Damper43
- Bleeding and Filling the Damper45
- Filling the Damper with Nitrogen47
- Installing the Spring47
05/Exhaust49
- Removing the Exhaust Manifold49
- Installing Exhaust Manifold49
- Removing the Main Silencer50
- Installing the Main Silencer51
06/Air Filter53
- Removing the Air Filter53
- Installing the Air Filter53
- Removing the Air Filter Box53
- Installing the Air Filter Box54
07/Fuel Tank, Seat, Trim56
- Opening Filler Cap56
- Closing Filler Cap56
- Removing the Seat56
- Mounting the Seat56
- Taking off the Side Cover56
- Mounting the Side Cover57
- Checking the Fuel Pressure57
- Changing the Fuel Filter58
09/Front Wheel61
- Removing Front Wheel61
- Installing the Front Wheel61
- Checking the Tire Air Pressure62
- Checking the Tire Condition62
- Checking the Brake Discs63
10/Rear Wheel64
- Removing Rear Wheel64
- Installing the Rear Wheel64
- Checking the Chain Tension65
- Adjusting the Chain Tension65
- Adjusting Chain Guide66
- Checking the Chain, Rear Sprocket and Engine Sprocket66
- Cleaning the Chain67
- Checking the Rear Hub Rubber Dampers68
- Checking the Spoke Tension68
- Checking the Rim Run-Out69
11/Wiring Harness, Battery70
- Removing the Battery70
- Installing the Battery70
- Disconnecting the Battery70
- Connecting the Battery71
- Recharging the Battery71
- Checking the Charging Voltage72
- Changing the Main Fuse72
- Changing Fuses of Individual Power Consumers73
- Adjusting the Engine Characteristic74
13/Brake System75
- Checking the Front Brake Linings75
- Changing the Front Brake Linings75
- Adjusting the Basic Position of the Hand Brake Lever76
- Checking the Front Brake Fluid Level76
- Adding Front Brake Fluid77
- Changing the Front Brake Fluid77
- Checking the Rear Brake Linings78
- Changing Rear Brake Linings79
- Checking the Free Travel of Foot Brake Lever80
- Adjusting the Basic Position of the Foot Brake Lever80
- Checking Rear Brake Fluid Level81
- Adding Rear Brake Fluid81
- Changing the Rear Brake Fluid82
14/Light System, Instruments84
- Setting Kilometers or Miles84
- Setting the Clock84
- Combination Instrument - Setting/Resetting TRIP 184
- Combination Instrument - Setting/Resetting TRIP 285
- Combination Instrument - Setting the Wheel Circumference85
- Checking the Headlight Setting86
- Adjusting the Headlight Range86
- Removing the Headlight Mask with the Headlight86
- Installing the Headlight Mask with the Headlight87
- Changing the Parking Light Bulb87
- Changing the Headlight Bulb88
- Changing the Flasher Bulb88
30/Engine90
- Removing the Engine90
- Installing the Engine92
30/Disassembling the Engine96
- Clamping Engine into Engine Work Stand96
- Draining the Engine Oil96
- Removing Starter Motor96
- Removing Valve Cover96
- Removing the Alternator Cover97
- Removing Spacer97
- Removing Gear Position Sensor97
- Removing Oil Filter97
- Removing Thermostat98
- Setting Engine to Ignition Top Dead Center98
- Removing Water Pump Wheel98
- Removing Clutch Cover99
- Removing Spacer and Spring99
- Removing Spark Plug99
- Removing Timing Chain Tensioner100
- Removing Camshafts100
- Removing Cylinder Head100
- Removing Piston100
- Removing Rotor101
- Removing Timing Chain Rails101
- Removing Timing Chain and Timing Chain Sprocket102
- Removing Crankshaft Position Sensor102
- Removing Clutch Cage102
- Removing Primary Gear104
- Removing Starter Drive104
- Removing Shift Shaft104
- Removing Shift Drum Locating104
- Removing Locking Lever105
- Removing Oil Pumps105
- Removing Left Engine Case105
- Removing Crankshaft and Balancer Shaft106
- Removing Transmission Shafts106
30/Engine - Work on Individual Parts108
- Work on the Right Section of the Engine Case108
- Work on the Left Section of the Engine Case109
- Work on the Clutch Cover110
- Removing Crankshaft Bearing Inner Ring111
- Removing Balancer Shaft Drive Wheel111
- Changing the Conrod Bearing111
- Checking Crankshaft Run-Out at Bearing Pin113
- Installing Balancer Shaft Drive Wheel113
- Installing Crankshaft Bearing Inner Ring113
- Measuring Axial Clearance of Crankshaft and Balancer Shaft114
- Cylinder - Nikasil Coating114
- Checking/Measuring the Cylinder115
- Checking/Measuring the Piston115
- Checking Piston Ring End Gap116
- Checking Piston/Cylinder Mounting Clearance117
- Checking Oil Pumps for Wear117
- Replacing Autodecompressor117
- Preparing Timing Chain Tensioner for Installation118
- Checking Timing Assembly119
- Removing Rocker Arm119
- Changing Camshaft Bearing119
- Removing Valves120
- Checking Valves121
- Checking Valve Springs121
- Checking Valve Spring Retainer121
- Checking Cylinder Head121
- Installing Valves122
- Installing Rocker Arm123
- Dismantling Antihopping Clutch123
- Checking the Clutch124
- Preassembling Antihopping Clutch125
- Checking Shift Mechanism126
- Preassembling Shift Shaft126
- Disassembling the Main Shaft127
- Dismantling Countershaft127
- Checking the Transmission128
- Assembling the Main Shaft129
- Assembling Countershaft130
- Checking Electric Starter Drive131
- Removing Freewheel131
- Checking Freewheel132
- Installing Freewheel132
30/Assembling the Engine134
- Installing Transmission Shafts134
- Installing Crankshaft and Balancer Shaft135
- Installing Left Engine Case135
- Installing Oil Pumps136
- Installing Locking Lever136
- Installing Shift Drum Locating136
- Installing Shift Shaft137
- Installing Starter Drive137
- Installing Primary Gear137
- Installing Clutch Cage138
- Installing Crankshaft Position Sensor139
- Installing Timing Chain and Timing Chain Sprocket139
- Installing Timing Chain Rails140
- Installing Rotor140
- Adjusting Crankshaft Position Sensor Distance140
- Setting Engine to Top Dead Center141
- Installing Piston141
- Installing Cylinder Head142
- Installing Camshafts143
- Installing Timing Chain Tensioner143
- Checking Valve Clearance144
- Adjusting Valve Clearance144
- Installing Spark Plug145
- Installing Spacer and Spring145
- Installing Clutch Cover145
- Mounting Water Pump Cover146
- Installing Thermostat146
- Installing the Oil Filter146
- Installing Gear Position Sensor147
- Installing the Spacer147
- Installing Oil Screens148
- Installing Alternator Cover148
- Installing Starter Motor149
- Installing Valve Cover149
- Taking Engine off Universal Mounting Rack149
32/Clutch150
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch150
35/Water Pump, Cooling System151
- Draining Coolant151
- Filling the Cooling System151
- Checking the Antifreeze and Coolant Level152
- Checking the Coolant Level153
38/Lubrication System154
- Oil Circuit154
- Checking the Engine Oil Level154
- Checking the Engine Oil Pressure155
- Changing the Engine Oil and Filter, Cleaning the Oil Screens156
- Draining Engine Oil156
- Removing the Oil Filter157
- Installing the Oil Filter157
- Cleaning the Oil Screens158
- Filling up with Engine Oil159
- Adding Engine Oil159
39/Ignition System160
- Alternator - Checking the Stator Winding160
- Checking the Spark Plug Connector160
- Ignition Coil - Checking the Secondary Winding161
41/Throttle Valve Body162
- Checking the Basic Setting of the Motor Drive162
- Adjusting the Basic Setting of the Motor Drive163
- Flashing the EFI Control Unit And/Or the EPT Control Unit166
- Requesting the Enabling Code167
- Coding the EFI Control Unit And/Or EPT Control Unit168
Technical Data - Engine170
- Capacity - Engine Oil170
- Capacity - Coolant170
Technical Data - Tolerance, Wear Limits of Engine171
Technical Data - Engine Tightening Torques173
Technical Data - Chassis175
- Lighting Equipment175
- Capacity - Fuel176
Technical Data - Fork177
Technical Data - Shock Absorber178
Technical Data - Chassis Tightening Torques179
Cleaning/Protective Treatment181
- Cleaning the Motorcycle181
- Protective Treatment for Winter Operation182
Storage183
- Putting into Operation after Storage183
Service Schedule184
Wiring Diagram186
- 184186
- 186188
- 188190
- 190192
- 192194
- 194196
- 196198
- 198200
- 200202
- 202204
Substances206
Auxiliary Substances208
Special Tools210
Standards222
Index223

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