KTM 2008 690 SMC EU - Page 2

KTM 2008 690 SMC EU

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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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