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18 SHIFT MECHANISM 176

G00777-10

–

Lubricate O-ring



of the new gear position sensor.

– Position the gear position sensor.



engages in drill hole



G00776-10

–

Mount and tighten screws



Guideline

Screw, gear position sen-

sor

M5x16 5 Nm

(3.7 lbf ft)

Loctite

243™

G00775-10

–

Secure the wiring harness with cable binder



G00774-10

–

Connect plug-in connector



– Route the cable without tension.

G00773-10

–

Secure the connector with cable binder



G00772-11

– Position the engine sprocket cover.

–

Mount and tighten screw



Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–

Mount and tighten screw



Guideline

Remaining screws, chassis M8 25 Nm

(18.4 lbf ft)

Finishing work

– Program the gear position sensor. ( p. 177)

– Remove the motorcycle from the lift stand. ( p. 11)

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 Information9
- 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 Legs17
- Cleaning the Dust Boots of the Fork Legs17
- Removing the Fork Protector17
- Installing the Fork Protector18
- Removing Fork Legs18
- Installing the Fork Legs19
- Disassembling the Fork Legs20
- Checking the Fork Legs23
- Assembling the Fork Legs24
- Checking the Steering Head Bearing Play28
- Adjusting the Steering Head Bearing Play28
7 Handlebar, Controls30
- Handlebar Position30
- Adjusting the Handlebar Position30
- Changing the Throttle Grip30
8 Shock Absorber, Swingarm35
- Adjusting the High-Speed Compression Damping of the Shock Absorber35
- Adjusting the Low-Speed Compression Damping of the Shock Absorber35
9 Exhaust55
- Removing the Manifold55
- Installing the Manifold56
- Removing the Main Silencer57
- Installing the Main Silencer58
10 Air Filter59
- Removing the Air Filter59
- Installing the Air Filter59
- Removing the Air Filter Box59
- Installing the Air Filter Box61
11 Fuel Tank, Seat, Trim63
- Opening the Filler Cap63
- Closing Filler Cap63
- Removing the Seat63
- Mounting the Seat64
- Taking off the Side Cover64
- Mounting the Side Cover64
- Checking the Fuel Pressure64
- Changing the Fuel Filter66
- Changing the Fuel Pump69
12 Wheels72
- Checking the Tire Air Pressure72
- Checking the Tire Condition72
- Checking the Brake Discs73
- Checking the Spoke Tension73
- Checking the Rim Run-Out74
- Front Wheel74
- Removing Front Wheel74
- Installing the Front Wheel75
- Removing the Brake Disc of the Front Brake76
- Installing the Brake Disc of the Front Brake76
- Rear Wheel76
- Removing Rear Wheel76
- Installing the Rear Wheel77
- Removing the Brake Disc of the Rear Brake78
- Installing the Brake Disc of the Rear Brake78
- Checking the Chain Tension79
- Adjusting the Chain Tension79
- Adjusting Chain Guide80
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide80
- Cleaning the Chain82
- Checking the Rear Hub Rubber Dampers82
13 Wiring Harness, Battery84
- Removing the Battery84
- Installing the Battery84
- Disconnecting the Battery85
- Connecting the Battery85
- Recharging the Battery85
- Checking the Charging Voltage86
- Checking the Quiescent Current87
- Changing the Main Fuse87
- Changing Fuses of Individual Power Consumers88
- Adjusting the Engine Characteristic89
14 Brake System91
- Checking the Front Brake Linings91
- Changing the Brake Linings of the Front Brake91
- Adjusting the Basic Position of the Hand Brake Lever92
- Checking Brake Fluid Level of Front Brake92
- Adding Front Brake Fluid93
- Changing the Front Brake Fluid94
- Checking the Rear Brake Linings95
- Changing the Rear Brake Linings95
- Checking the Free Travel of Foot Brake Lever97
- Adjusting the Basic Position of the Foot Brake Lever97
- Checking Rear Brake Fluid Level97
- Adding Rear Brake Fluid98
- Changing the Rear Brake Fluid99
15 Lighting System, Instruments101
- Combination Instrument101
- Setting Kilometers or Miles101
- Setting the Clock101
- Setting/Resetting Display TRIP 1101
- Setting/Resetting Display TRIP 2101
- Setting the Wheel Circumference102
- Checking the Headlight Setting103
- Adjusting the Headlight Range103
- Removing the Headlight Mask with the Headlight103
- Installing the Headlight Mask with the Headlight104
- Changing the Parking Light Bulb104
- Changing the Headlight Bulb105
- Changing the Turn Signal Bulb106
16 Engine107
- Removing the Engine107
- Installing the Engine109
- Disassembling the Engine113
- Clamping the Engine into the Engine Assembly Stand113
- Draining the Engine Oil113
- Removing the Starter Motor114
- Removing the Valve Cover114
- Removing the Alternator Cover114
- Removing the Spacer114
- Removing the Gear Position Sensor115
- Removing the Oil Filter115
- Removing the Thermostat115
- Setting Engine to Ignition Top Dead Center115
- Removing the Spark Plugs116
- Removing the Timing Chain Tensioner116
- Removing the Camshafts116
- Removing the Cylinder Head117
- Removing the Piston117
- Removing the Water Pump Impeller118
- Removing the Rotor118
- Removing the Timing Chain Rails119
- Removing the Timing Chain and Timing Chain Sprocket119
- Removing the Ignition Pulse Generator120
- Removing the Clutch Cover120
- Removing the Spacer and Spring120
- Removing the Clutch Basket121
- Removing the Primary Gear122
- Removing the Starter Drive122
- Removing Shift Shaft123
- Removing Shift Drum Locating123
- Removing Locking Lever124
- Removing the Oil Pumps124
- Removing the Left Engine Case125
- Removing the Crankshaft and Balancer Shaft126
- Removing the Transmission Shafts126
- Work on Individual Parts127
- Work on the Right Section of the Engine Case127
- Work on the Left Section of the Engine Case128
- Work on the Clutch Cover130
- Removing Crankshaft Bearing Inner Ring130
- Removing Balancer Shaft Drive Wheel130
- Changing the Connecting Rod, Conrod Bearing, and Crank Pin130
- Checking Crankshaft Run-Out at Bearing Pin132
- Installing Balancer Shaft Drive Wheel132
- Installing Crankshaft Bearing Inner Ring133
- Measuring Axial Clearance of Crankshaft and Balancer Shaft133
- Cylinder - Nikasil ® Coating134
- Checking/Measuring the Cylinder134
- Checking/Measuring the Piston135
- Checking Piston Ring End Gap136
- Determining the Piston/Cylinder Mounting Clearance136
- Checking the Oil Pumps for Wear136
- Replacing Autodecompressor137
- Preparing Timing Chain Tensioner for Installation138
- Checking the Timing Assembly139
- Removing the Rocker Arm140
- Changing the Camshaft Bearing140
- Removing the Valves141
- Checking the Valves142
- Checking Valve Springs142
- Checking Valve Spring Retainer142
- Checking the Cylinder Head142
- Installing the Valves143
- Installing the Rocker Arm144
- Disassembling the Antihopping Clutch144
- Checking the Clutch145
- Preassembling the Antihopping Clutch146
- Checking the Shift Mechanism147
- Preassembling the Shift Shaft148
- Disassembling the Main Shaft149
  - Disassembling the Countershaft150
  - Checking the Transmission150
  - Assembling the Main Shaft152
  - Assembling the Countershaft153
  - Checking the Starter Drive154
  - Checking Freewheel155
  - Removing Freewheel155
  - Installing Freewheel155
  - Assembling the Engine156
  - Installing the Transmission Shafts156
  - Installing Crankshaft and Balancer Shaft157
  - Installing the Left Engine Case158
  - Installing the Oil Pumps159
  - Installing Locking Lever160
  - Installing Shift Drum Locating160
  - Installing Shift Shaft160
  - Installing the Starter Drive160
  - Installing the Primary Gear161
  - Installing the Clutch Basket161
  - Installing the Spacer and Spring163
  - Installing the Clutch Cover163
  - Installing the Ignition Pulse Generator164
  - Installing Timing Chain and Timing Chain Sprocket164
  - Installing the Timing Chain Rails164
  - Installing the Rotor165
  - Adjusting Crankshaft Position Sensor Distance165
  - Setting Engine to Top Dead Center166
  - Mounting the Water Pump Cover166
  - Installing Piston166
  - Installing the Cylinder Head168
  - Installing the Camshafts169
  - Installing Timing Chain Tensioner169
  - Checking Valve Clearance170
  - Adjusting the Valve Clearance171
  - Installing the Spark Plugs172
  - Installing the Thermostat172
  - Installing the Oil Filter172
  - Installing the Gear Position Sensor173
  - Installing the Spacer173
  - Installing the Alternator Cover173
  - Installing Oil Screens174
  - Installing the Starter Motor174
  - Installing the Valve Cover175
  - Removing the Engine from the Engine Assembly Stand175
17 Clutch176
- Checking/Rectifying the Fluid Level of the Hydraulic Clutch176
- Changing the Hydraulic Clutch Fluid176
18 Shift Mechanism177
- Changing the Gear Position Sensor177
- Programming the Gear Position Sensor179
19 Water Pump, Cooling System180
- Draining the Coolant180
20 Lubrication System183
- Oil Circuit183
- Checking the Engine Oil Level183
- Checking the Engine Oil Pressure184
- Changing the Engine Oil and Filter, Cleaning the Oil Screens185
- Draining the Engine Oil185
- Removing the Oil Filter186
- Installing the Oil Filter186
- Cleaning the Oil Screens187
- Filling up with Engine Oil188
- Adding Engine Oil188
21 Ignition189
- Alternator - Checking the Stator Winding189
- Checking the Spark Plug Connector189
- Ignition Coil - Checking the Secondary Winding190
22 Throttle Valve Body191
- Performing the Initialization Run191
23 Technical Data192
- Engine192
- Engine Tolerance, Wear Limits192
- Engine Tightening Torques194
- Capacities195
- Engine Oil195
- Coolant195
- Fuel195
- Chassis196
- Electrical System196
- Tires197
- Fork197
- Shock Absorber197
- Chassis Tightening Torques198
24 Cleaning/Protective Treatment200
- Cleaning the Motorcycle200
- Checks and Maintenance Steps for Winter Operation201
25 Storage202
- Preparing for Use after Storage202
26 Service Schedule203
27 Wiring Diagram204
- 202204
- 204206
- 206208
- 208210
- 210212
- 212214
- 214216
- 216218
- 218220
- 220222
- 222224
28 Substances226
29 Auxiliary Substances228
30 Special Tools230
31 Standards243
- Index244

Brand	KTM
Model	2014 690 SMC R EU
Category	Motorcycle
Language	English

KTM 2014 690 SMC R EU User Manual

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KTM 2014 690 SMC R EU Specifications

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