KTM 2011 690 SMC EU - Repair Manual

KTM 2011 690 SMC EU

229 pages

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REPAIR MANUAL 2011

690 SMC EU

690 SMC AUS/UK

Art. no. 3206122en

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Repair Manual8
- Degrees of Risk and Symbols8
- Work Rules8
3 Important Notes9
- Guarantee, Warranty9
- Operating and Auxiliary Substances9
- Spare Parts, Accessories9
- Figures9
4 Serial Numbers10
- Chassis Number10
- Type Label10
- Engine Number10
- Key Number10
- Fork Part Number10
- Shock Absorber Part Number11
5 Motorcycle12
- Raising the Motorcycle with the Rear Wheel Stand12
- Taking the Motorcycle off of the Rear Wheel Stand12
- Raising the Motorcycle with the Front Wheel Stand12
- Taking the Motorcycle off of the Front Wheel Stand12
- Raising the Motorcycle with the Lift Stand13
- Removing the Motorcycle from the Lift Stand13
- Raising the Motorcycle with the Work Stand13
- Removing the Motorcycle from the Work Stand14
- Starting14
- Starting the Motorcycle to Make Checks15
6 Fork, Triple Clamp16
- Adjusting the Compression Damping of the Fork16
- Adjusting the Rebound Damping of the Fork16
- Bleeding the Fork Legs16
- Cleaning the Dust Boots of the Fork Legs17
- Removing the Fork Protector17
- Installing the Fork Protector17
- Removing Fork Legs18
- Installing the Fork Legs19
- Servicing the Fork20
- Disassembling the Fork Legs21
- Checking the Fork Legs24
- Assembling the Fork Legs25
- Checking the Steering Head Bearing Play29
- Adjusting the Steering Head Bearing Play30
7 Handlebar, Controls31
- Handlebar Position31
- Adjusting Handlebar Position31
- Checking the Routing of the Throttle Cable31
- Checking the Play in the Throttle Cable32
- Adjusting the Play in the Throttle Cable32
8 Shock Absorber, Swingarm34
- Adjusting the High-Speed Compression Damping of the Shock Absorber34
- Adjusting the Low-Speed Compression Damping of the Shock Absorber34
- Adjusting the Rebound Damping of the Shock Absorber35
9 Exhaust54
- Removing the Manifold54
- Installing the Manifold55
- Removing the Main Silencer56
- Installing the Main Silencer56
10 Air Filter58
- Removing the Air Filter58
- Installing the Air Filter58
- Removing the Air Filter Box58
- Installing the Air Filter Box59
11 Fuel Tank, Seat, Trim61
- Opening the Filler Cap61
- Closing Filler Cap61
- Removing the Seat61
- Mounting the Seat62
- Taking off the Side Cover62
- Mounting the Side Cover62
- Checking the Fuel Pressure62
- Changing the Fuel Filter63
- Changing the Fuel Pump66
12 Wheels70
- Checking the Tire Air Pressure70
- Checking the Tire Condition70
- Checking the Brake Discs71
- Checking the Spoke Tension71
- Checking the Rim Run-Out72
- Front Wheel72
- Removing Front Wheel72
- Installing the Front Wheel73
- Removing the Brake Disc of the Front Brake74
- Installing the Brake Disc of the Front Brake74
- Rear Wheel74
- Removing Rear Wheel74
- Installing the Rear Wheel75
- Removing the Brake Disc of the Rear Brake75
- Installing the Brake Disc of the Rear Brake76
- Checking the Chain Tension76
- Adjusting the Chain Tension76
- Adjusting Chain Guide77
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide77
- Cleaning the Chain79
- Checking the Rear Hub Rubber Dampers79
13 Wiring Harness, Battery81
- Removing the Battery81
- Installing the Battery81
- Disconnecting the Battery81
- Connecting the Battery82
- Recharging the Battery82
- Checking the Charging Voltage83
- Changing the Main Fuse84
- Changing Fuses of Individual Power Consumers84
- Adjusting the Engine Characteristic85
14 Brake System87
- Checking the Front Brake Linings87
- Changing the Brake Linings of the Front Brake87
- Adjusting the Basic Position of the Hand Brake Lever88
- Checking the Front Brake Fluid Level88
- Adding Front Brake Fluid89
- Changing the Front Brake Fluid90
- Checking the Rear Brake Linings90
- Changing the Rear Brake Linings91
- Checking the Free Travel of Foot Brake Lever92
- Adjusting the Basic Position of the Foot Brake Lever93
- Checking Rear Brake Fluid Level93
- Adding Rear Brake Fluid94
- Changing the Rear Brake Fluid94
15 Lighting System, Instruments96
- Combination Instrument96
- Setting Kilometers or Miles96
- Setting the Clock96
- Setting/Resetting Display TRIP 196
- Setting/Resetting Display TRIP 296
- Setting the Wheel Circumference97
- Checking the Headlight Setting98
- Adjusting the Headlight Range98
- Removing the Headlight Mask with the Headlight98
- Installing the Headlight Mask with the Headlight99
- Changing the Parking Light Bulb99
- Changing the Headlight Bulb100
- Changing the Turn Signal Bulb101
16 Engine102
- Removing the Engine102
- Installing the Engine104
- Engine Disassembly108
- Clamping the Engine into the Engine Assembly Stand108
- Draining the Engine Oil108
- Removing Starter Motor108
- Removing Valve Cover109
- Removing the Alternator Cover109
- Removing Spacer109
- Removing Gear Position Sensor109
- Removing Oil Filter110
- Removing Thermostat110
- Setting Engine to Ignition Top Dead Center110
- Removing Water Pump Wheel111
- Removing Clutch Cover111
- Removing Spacer and Spring111
- Removing Spark Plug112
- Removing Timing Chain Tensioner112
- Removing Camshafts112
- Removing Cylinder Head112
- Removing Piston113
- Removing Rotor113
- Removing Timing Chain Rails114
- Removing Timing Chain and Timing Chain Sprocket114
- Removing Crankshaft Position Sensor114
- Removing Clutch Cage115
- Removing Primary Gear116
- Removing Starter Drive116
- Removing Shift Shaft116
- Removing Shift Drum Locating116
- Removing Locking Lever117
- Removing Oil Pumps117
- Removing Left Engine Case117
- Removing Crankshaft and Balancer Shaft118
- Removing Transmission Shafts118
- Work on Individual Parts119
- Work on the Right Section of the Engine Case119
- Work on the Left Section of the Engine Case121
- Work on the Clutch Cover122
- Removing Crankshaft Bearing Inner Ring123
- Removing Balancer Shaft Drive Wheel123
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin123
- Checking Crankshaft Run-Out at Bearing Pin125
- Installing Balancer Shaft Drive Wheel125
- Installing Crankshaft Bearing Inner Ring125
- Measuring Axial Clearance of Crankshaft and Balancer Shaft126
- Cylinder - Nikasil ® Coating126
- Checking/Measuring the Cylinder127
- Checking/Measuring the Piston127
- Checking Piston Ring End Gap128
- Checking Piston/Cylinder Mounting Clearance128
- Checking Oil Pumps for Wear129
- Replacing Autodecompressor129
- Preparing Timing Chain Tensioner for Installation130
- Checking Timing Assembly130
- Removing Rocker Arm131
- Changing Camshaft Bearing131
- Removing Valves132
- Checking Valves132
- Checking Valve Springs133
- Checking Valve Spring Retainer133
- Checking Cylinder Head133
- Installing Valves134
- Installing Rocker Arm135
- Disassembling the Antihopping Clutch135
- Checking the Clutch135
- Preassembling the Antihopping Clutch137
  - Checking Shift Mechanism138
  - Preassembling Shift Shaft138
  - Disassembling the Main Shaft139
  - Dismantling Countershaft139
  - Checking the Transmission140
  - Assembling the Main Shaft141
  - Assembling Countershaft142
  - Checking the Starter Drive143
  - Removing Freewheel143
  - Checking Freewheel144
  - Installing Freewheel144
  - Engine Assembly145
  - Installing Transmission Shafts145
  - Installing Crankshaft and Balancer Shaft146
  - Installing Left Engine Case147
  - Installing Oil Pumps147
  - Installing Locking Lever148
  - Installing Shift Drum Locating148
  - Installing Shift Shaft148
  - Installing Starter Drive148
  - Installing Primary Gear149
  - Installing Clutch Cage149
  - Installing Crankshaft Position Sensor150
  - Installing Timing Chain and Timing Chain Sprocket151
  - Installing Timing Chain Rails151
  - Installing Rotor151
  - Adjusting Crankshaft Position Sensor Distance152
  - Setting Engine to Top Dead Center152
  - Installing Piston152
  - Installing Cylinder Head154
  - Installing Camshafts154
  - Installing Timing Chain Tensioner155
  - Checking Valve Clearance155
  - Adjusting Valve Clearance156
  - Installing Spark Plug157
  - Installing Spacer and Spring157
  - Installing Clutch Cover157
  - Mounting Water Pump Cover157
  - Installing Thermostat158
  - Installing the Oil Filter158
  - Installing Gear Position Sensor158
  - Installing the Spacer159
  - Installing Oil Screens159
  - Installing Alternator Cover160
  - Installing Starter Motor160
  - Installing Valve Cover161
  - Removing the Engine from the Engine Assembly Stand161
17 Clutch162
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch162
- Changing the Hydraulic Clutch Fluid162
18 Water Pump, Cooling System163
- Draining the Coolant163
- Filling/Bleeding the Cooling System163
- Checking the Antifreeze and Coolant Level164
- Checking the Coolant Level165
19 Lubrication System166
- Oil Circuit166
- Checking the Engine Oil Level166
- Checking the Engine Oil Pressure167
- Changing the Engine Oil and Filter, Cleaning the Oil Screens168
- Draining the Engine Oil168
- Removing the Oil Filter169
- Installing the Oil Filter169
- Cleaning the Oil Screens170
- Filling up with Engine Oil171
- Adding Engine Oil171
20 Ignition System172
- Alternator - Checking the Stator Winding172
- Checking the Spark Plug Connector172
- Ignition Coil - Checking the Secondary Winding173
21 Technical Data174
- Engine174
- Engine Tolerance, Wear Limits174
- Engine Tightening Torques176
- Capacities177
- Engine Oil177
- Coolant177
- Fuel177
- Chassis177
- Electrical System178
- Tires178
- Fork179
- Shock Absorber179
- Chassis Tightening Torques180
22 Cleaning/Protective Treatment182
- Cleaning the Motorcycle182
- Checks and Maintenance Steps for Winter Operation183
23 Storage184
- Preparing for Use after Storage184
24 Service Schedule185
25 Wiring Diagram188
- 186188
- 188190
- 190192
- 192194
- 194196
- 196198
- 198200
- 200202
- 202204
- 204206
26 Substances208
27 Auxiliary Substances210
28 Special Tools212
29 Standards224
- Index225

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