KTM 690 SMC 2008, Repair Manual

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CONTENTS
2
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number/type label (690 SMC EU,
690 SMC AUS/UK).......................................................... 7
Chassis number/type label (690 SMC USA)........................ 7
Key number .................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 8
Shock absorber part number............................................. 8
MOTORCYCLE..................................................................... 9
Raising the motorcycle with the rear wheel stand................ 9
Taking the motorcycle off of the rear wheel stand ............... 9
Raising the motorcycle with the front wheel stand .............. 9
Taking the motorcycle off of the front wheel stand .............. 9
Raising the motorcycle with the work stand...................... 10
Removing the motorcycle from the work stand.................. 10
Starting ........................................................................ 11
Starting the motorcycle to make checks........................... 11
01/FORK, TRIPLE CLAMP.................................................. 12
Adjusting compression damping of fork ........................... 12
Adjusting rebound damping of fork.................................. 12
Bleeding the fork legs .................................................... 12
Cleaning the dust boots of the fork legs ........................... 13
Removing the fork protector............................................ 13
Installing the fork protector ............................................ 13
Removing fork legs ........................................................ 14
Installing the fork legs ................................................... 15
Servicing the fork .......................................................... 16
Disassembling the fork legs ............................................ 17
Checking the fork legs.................................................... 20
Assembling the fork legs ................................................ 21
Checking the steering head bearing play .......................... 25
Adjusting the steering head bearing play.......................... 26
02/HANDLEBAR, INSTRUMENTS....................................... 27
Handlebar position ........................................................ 27
Adjusting handlebar position .......................................... 27
Checking the play in the throttle cable............................. 27
Adjusting the play in the throttle cable ............................ 28
04/SHOCK ABSORBER, SWINGARM................................... 29
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 29
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 29
Adjusting the rebound damping of the shock absorber....... 30
Measuring the unloaded rear wheel sag............................ 30
Checking the static sag of the shock absorber .................. 30
Checking the riding sag of the shock absorber .................. 31
Adjusting the spring preload of the shock absorber ........... 31
Adjusting the riding sag ................................................. 32
Removing the shock absorber ......................................... 32
Installing the shock absorber .......................................... 33
Servicing the shock absorber .......................................... 34
Removing the spring ...................................................... 35
Dismantling the damper ................................................. 35
Disassembling the piston rod .......................................... 36
Checking the damper ..................................................... 37
Removing the heim joint ................................................ 38
Installing the heim joint ................................................. 39
Assembling the piston rod .............................................. 40
Assembling the damper.................................................. 41
Bleeding and filling the damper ...................................... 43
Filling the damper with nitrogen ..................................... 45
Installing the spring....................................................... 45
05/EXHAUST .................................................................... 47
Removing the exhaust manifold ...................................... 47
Installing exhaust manifold............................................. 47
Removing the main silencer............................................ 48
Installing the main silencer ............................................ 49
06/AIR FILTER.................................................................. 51
Removing the air filter ................................................... 51
Installing the air filter .................................................... 51
Removing the air filter box ............................................. 51
Installing the air filter box .............................................. 52
07/FUEL TANK, SEAT, TRIM.............................................. 54
Opening filler cap.......................................................... 54
Closing filler cap ........................................................... 54
Removing the seat ......................................................... 54
Mounting the seat ......................................................... 54
Taking off the side cover ................................................ 54
Mounting the side cover ................................................. 55
Checking the fuel pressure ............................................. 55
Changing the fuel filter .................................................. 56
09/FRONT WHEEL ............................................................ 59
Removing front wheel .................................................... 59
Installing the front wheel................................................ 59
Checking the tire air pressure ......................................... 60
Checking the tire condition............................................. 60
Checking the brake discs................................................ 61
10/REAR WHEEL .............................................................. 62
Removing rear wheel...................................................... 62
Installing the rear wheel................................................. 62
Checking the chain tension ............................................ 63
Adjusting the chain tension ............................................ 63
Adjusting chain guide .................................................... 64
Checking the chain, rear sprocket and engine sprocket...... 64
Cleaning the chain......................................................... 65
Checking the rear hub rubber dampers ............................ 66
Checking the spoke tension ............................................ 66
Checking the rim run-out................................................ 67
11/WIRING HARNESS, BATTERY ....................................... 68
Removing the battery ..................................................... 68
Installing the battery...................................................... 68
Disconnecting the battery............................................... 68
Connecting the battery ................................................... 69
Recharging the battery ................................................... 69
Checking the charging voltage ........................................ 70
Changing the main fuse ................................................. 70
Changing fuses of individual power consumers ................. 71
Adjusting the engine characteristic.................................. 72
13/BRAKE SYSTEM........................................................... 73
Checking the front brake linings...................................... 73
Changing the front brake linings ..................................... 73
Adjusting the basic position of the hand brake lever.......... 74
Checking the front brake fluid level ................................. 74
Adding front brake fluid ................................................. 75
Changing the front brake fluid ........................................ 75
Checking the rear brake linings ....................................... 76
Changing rear brake linings ............................................ 77
Checking the free travel of foot brake lever....................... 78
Adjusting the basic position of the foot brake lever ........... 78
Checking rear brake fluid level........................................ 79
Adding rear brake fluid .................................................. 79