KTM 2013 690 SMC R EU - Page 223

KTM 2013 690 SMC R EU

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28 SPECIAL TOOLS 221

Protecting sleeve

200635-10

Art. no.: T1401

Gripping tool

200639-10

Art. no.: T14026S1

Assembly tool

200634-10

Art. no.: T1402S

Open-end wrench

200640-10

Art. no.: T14032

Clamping stand

200637-10

Art. no.: T1403S

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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