KTM 2013 690 SMC R EU User Manual

KTM 2013 690 SMC R EU

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REPAIR MANUAL 2013

690 SMC R EU

690 SMC R AUS/UK

Art. no. 3206153en

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 Stand13
- Raising the Motorcycle with a 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 the 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 Manifold54
- Removing the Main Silencer55
- 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 Pump67
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 Tension77
- Adjusting Chain Guide77
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide77
- Cleaning the Chain79
- Checking the Rear Hub Rubber Dampers80
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 Linings91
- Changing the Rear Brake Linings91
- Checking the Free Travel of Foot Brake Lever93
- Adjusting the Basic Position of the Foot Brake Lever93
- Checking Rear Brake Fluid Level93
- Adding Rear Brake Fluid94
- Changing the Rear Brake Fluid95
15 Lighting System, Instruments97
- Combination Instrument97
- Setting Kilometers or Miles97
- Setting the Clock97
- Setting/Resetting Display TRIP 197
- Setting/Resetting Display TRIP 297
- Setting the Wheel Circumference98
- Checking the Headlight Setting99
- Adjusting the Headlight Range99
- Removing the Headlight Mask with the Headlight99
- Installing the Headlight Mask with the Headlight100
- Changing the Parking Light Bulb100
- Changing the Headlight Bulb101
- Changing the Turn Signal Bulb102
16 Engine103
- Removing the Engine103
- Installing the Engine105
- Engine Disassembly109
- Clamping the Engine into the Engine Assembly Stand109
- Draining the Engine Oil109
- Removing Starter Motor109
- Removing Valve Cover110
- Removing the Alternator Cover110
- Removing Spacer110
- Removing Gear Position Sensor110
- Removing Oil Filter111
- Removing Thermostat111
- Setting Engine to Ignition Top Dead Center111
- Removing Water Pump Wheel112
- Removing Clutch Cover112
- Removing Spacer and Spring112
- Removing Spark Plug113
- Removing Timing Chain Tensioner113
- Removing Camshafts113
- Removing Cylinder Head113
- Removing Piston114
- Removing Rotor114
- Removing Timing Chain Rails115
- Removing Timing Chain and Timing Chain Sprocket115
- Removing Crankshaft Position Sensor115
- Removing Clutch Cage116
- Removing Primary Gear117
- Removing Starter Drive117
- Removing Shift Shaft117
- Removing Shift Drum Locating117
- Removing Locking Lever118
- Removing Oil Pumps118
- Removing Left Engine Case118
- Removing Crankshaft and Balancer Shaft119
- Removing Transmission Shafts119
- Work on Individual Parts120
- Work on the Right Section of the Engine Case120
- Work on the Left Section of the Engine Case122
- Work on the Clutch Cover123
- Removing Crankshaft Bearing Inner Ring124
- Removing Balancer Shaft Drive Wheel124
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin124
- Checking Crankshaft Run-Out at Bearing Pin126
- Installing Balancer Shaft Drive Wheel126
- Installing Crankshaft Bearing Inner Ring126
- Measuring Axial Clearance of Crankshaft and Balancer Shaft127
- Cylinder - Nikasil ® Coating127
- Checking/Measuring the Cylinder128
- Checking/Measuring the Piston128
- Checking Piston Ring End Gap129
- Checking Piston/Cylinder Mounting Clearance129
- Checking Oil Pumps for Wear130
- Replacing Autodecompressor130
- Preparing Timing Chain Tensioner for Installation131
- Checking Timing Assembly131
- Removing Rocker Arm132
- Changing Camshaft Bearing132
- Removing Valves133
- Checking Valves133
- Checking Valve Springs134
- Checking Valve Spring Retainer134
- Checking Cylinder Head134
- Installing Valves135
- Installing Rocker Arm136
- Disassembling the Antihopping Clutch136
- Checking the Clutch136
- Preassembling the Antihopping Clutch138
  - Checking Shift Mechanism139
  - Preassembling Shift Shaft139
  - Disassembling the Main Shaft140
  - Dismantling Countershaft140
  - Checking the Transmission141
  - Assembling the Main Shaft142
  - Assembling Countershaft143
  - Checking the Starter Drive144
  - Checking Freewheel144
  - Removing Freewheel145
  - Installing Freewheel145
  - Engine Assembly146
  - Installing Transmission Shafts146
  - Installing Crankshaft and Balancer Shaft147
  - Installing Left Engine Case148
  - Installing Oil Pumps148
  - Installing Locking Lever149
  - Installing Shift Drum Locating149
  - Installing Shift Shaft149
  - Installing Starter Drive149
  - Installing Primary Gear150
  - Installing Clutch Basket150
  - Installing Crankshaft Position Sensor151
  - Installing Timing Chain and Timing Chain Sprocket152
  - Installing Timing Chain Rails152
  - Installing Rotor152
  - Adjusting Crankshaft Position Sensor Distance153
  - Setting Engine to Top Dead Center153
  - Installing Piston153
  - Installing Cylinder Head155
  - Installing Camshafts155
  - Installing Timing Chain Tensioner156
  - Checking Valve Clearance156
  - Adjusting Valve Clearance157
  - Installing Spark Plug158
  - Installing Spacer and Spring158
  - Installing Clutch Cover158
  - Mounting Water Pump Cover158
  - Installing Thermostat159
  - Installing the Oil Filter159
  - Installing Gear Position Sensor159
  - Installing the Spacer160
  - Installing Oil Screens160
  - Installing Alternator Cover161
  - Installing the Starter Motor161
  - Installing Valve Cover162
  - Removing the Engine from the Engine Assembly Stand162
17 Clutch163
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch163
- Changing the Hydraulic Clutch Fluid163
18 Water Pump, Cooling System164
- Draining the Coolant164
- Filling/Bleeding the Cooling System164
- Checking the Antifreeze and Coolant Level165
- Checking the Coolant Level166
19 Lubrication System167
- Oil Circuit167
- Checking the Engine Oil Level167
- Checking the Engine Oil Pressure168
- Changing the Engine Oil and Filter, Cleaning the Oil Screens169
- Draining the Engine Oil169
- Removing the Oil Filter170
- Installing the Oil Filter170
- Cleaning the Oil Screens171
- Filling up with Engine Oil172
- Adding Engine Oil172
20 Ignition System173
- Alternator - Checking the Stator Winding173
- Checking the Spark Plug Connector173
- Ignition Coil - Checking the Secondary Winding174
21 Technical Data175
- Engine175
- Engine Tolerance, Wear Limits175
- Engine Tightening Torques177
- Capacities178
- Engine Oil178
- Coolant178
- Fuel178
- Chassis178
- Electrical System179
- Tires179
- Fork180
- Shock Absorber180
- Chassis Tightening Torques181
22 Cleaning/Protective Treatment183
- Cleaning the Motorcycle183
- Checks and Maintenance Steps for Winter Operation184
23 Storage185
- Preparing for Use after Storage185
24 Service Schedule186
25 Wiring Diagram188
- 186188
- 188190
- 190192
- 192194
- 194196
- 196198
- 198200
- 200202
- 202204
- 204206
26 Substances208
27 Auxiliary Substances210
28 Special Tools212
29 Standards225
- Index226

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KTM 2013 690 SMC R EU Specifications

General

Brand	KTM
Model	2013 690 SMC R EU
Category	Motorcycle
Language	English

Summary

Motorcycle Safety Guidelines and Warnings

General Safety Instructions

Crucial safety instructions for operating the vehicle and performing repairs.

Risk Degrees and Symbols Explained

Explanation of danger, warning, caution, and note symbols used in the manual.

Workshop Work Rules

Fork and Triple Clamp Maintenance

Adjusting Fork Damping Settings

How to adjust compression and rebound damping on the fork legs.

Fork Leg Removal and Installation

Checking Fork Legs

Steering Head Bearing Maintenance

Checking and Adjusting Steering Head Bearing Play

Method for inspecting and adjusting steering head bearing play for safe handling.

Rear Suspension (Shock Absorber) Service

Adjusting Shock Absorber Damping

Instructions for adjusting compression and rebound damping settings.

Checking Suspension Sag (Static and Riding)

Measuring static and riding sag to assess rear suspension setup.

Shock Absorber Removal and Installation

Shock Absorber Servicing Procedures

Engine Removal and Installation

Removing the Engine

Comprehensive steps required to safely remove the engine from the motorcycle frame.

Installing the Engine

Step-by-step guide for correctly installing the engine back into the frame.

Engine Disassembly and Reassembly

Engine Disassembly Procedures

Engine Reassembly Procedures

Brake System Maintenance

Front Brake System Service

Checking and changing front brake linings and fluid for optimal performance.

Rear Brake System Service

Inspecting and servicing rear brake linings and fluid levels.

Brake Fluid Level Checks and Changes

Procedures for checking and changing front and rear brake fluid.

Wheels and Chain Service

Wheel Removal and Installation

Chain Maintenance and Adjustment

Electrical System Checks

Fuse Replacement and Voltage Checks

Service Schedule and Standards

Recommended Service Schedule

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