KTM 690 SMC 2008, Руководство по ремонту

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CONTENTS
3
Changing the rear brake fluid.......................................... 80
14/LIGHT SYSTEM, INSTRUMENTS ................................... 82
Setting kilometers or miles ............................................. 82
Setting the clock ........................................................... 82
Combination instrument - setting/resetting TRIP 1............ 82
Combination instrument - setting/resetting TRIP 2............ 83
Combination instrument - setting the wheel
circumference ............................................................... 83
Checking the headlight setting........................................ 84
Adjusting the headlight range ......................................... 84
Removing the headlight mask with the headlight .............. 84
Installing the headlight mask with the headlight............... 85
Changing the parking light bulb ...................................... 85
Changing the headlight bulb........................................... 86
Changing the flasher bulb .............................................. 86
30/ENGINE....................................................................... 88
Removing the engine ..................................................... 88
Installing the engine ...................................................... 90
30/DISASSEMBLING THE ENGINE..................................... 94
Clamping engine into engine work stand .......................... 94
Draining the engine oil................................................... 94
Removing starter motor .................................................. 94
Removing valve cover..................................................... 94
Removing the alternator cover......................................... 95
Removing spacer ........................................................... 95
Removing gear position sensor ........................................ 95
Removing oil filter ......................................................... 95
Removing thermostat ..................................................... 96
Setting engine to ignition top dead center........................ 96
Removing water pump wheel .......................................... 96
Removing clutch cover ................................................... 97
Removing spacer and spring ........................................... 97
Removing spark plug ..................................................... 97
Removing timing chain tensioner .................................... 98
Removing camshafts...................................................... 98
Removing cylinder head ................................................. 98
Removing piston............................................................ 98
Removing rotor.............................................................. 99
Removing timing chain rails ........................................... 99
Removing timing chain and timing chain sprocket .......... 100
Removing crankshaft position sensor ............................. 100
Removing clutch cage.................................................. 100
Removing primary gear................................................. 102
Removing starter drive ................................................. 102
Removing shift shaft.................................................... 102
Removing shift drum locating ....................................... 102
Removing locking lever ................................................ 103
Removing oil pumps .................................................... 103
Removing left engine case............................................ 103
Removing crankshaft and balancer shaft........................ 104
Removing transmission shafts....................................... 104
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 106
Work on the right section of the engine case .................. 106
Work on the left section of the engine case .................... 107
Work on the clutch cover.............................................. 108
Removing crankshaft bearing inner ring ......................... 109
Removing balancer shaft drive wheel ............................. 109
Changing the conrod bearing ........................................ 109
Checking crankshaft run-out at bearing pin .................... 111
Installing balancer shaft drive wheel.............................. 111
Installing crankshaft bearing inner ring.......................... 111
Measuring axial clearance of crankshaft and balancer
shaft .......................................................................... 112
Cylinder - Nikasil
®
coating ............................................ 112
Checking/measuring the cylinder................................... 113
Checking/measuring the piston ..................................... 113
Checking piston ring end gap........................................ 114
Checking piston/cylinder mounting clearance ................. 115
Checking oil pumps for wear......................................... 115
Replacing autodecompressor ........................................ 115
Preparing timing chain tensioner for installation ............. 116
Checking timing assembly ............................................ 117
Removing rocker arm ................................................... 117
Changing camshaft bearing .......................................... 117
Removing valves.......................................................... 118
Checking valves........................................................... 119
Checking valve springs ................................................. 119
Checking valve spring retainer ...................................... 119
Checking cylinder head ................................................ 119
Installing valves .......................................................... 120
Installing rocker arm.................................................... 121
Dismantling antihopping clutch .................................... 121
Checking the clutch..................................................... 122
Preassembling antihopping clutch................................. 123
Checking shift mechanism ........................................... 124
Preassembling shift shaft ............................................. 124
Disassembling the main shaft ....................................... 125
Dismantling countershaft ............................................. 125
Checking the transmission............................................ 126
Assembling the main shaft ........................................... 127
Assembling countershaft .............................................. 128
Checking electric starter drive....................................... 129
Removing freewheel..................................................... 129
Checking freewheel...................................................... 130
Installing freewheel ..................................................... 130
30/ASSEMBLING THE ENGINE ........................................ 132
Installing transmission shafts ....................................... 132
Installing crankshaft and balancer shaft......................... 133
Installing left engine case ............................................ 133
Installing oil pumps ..................................................... 134
Installing locking lever ................................................. 134
Installing shift drum locating ........................................ 134
Installing shift shaft..................................................... 135
Installing starter drive .................................................. 135
Installing primary gear ................................................. 135
Installing clutch cage................................................... 136
Installing crankshaft position sensor.............................. 137
Installing timing chain and timing chain sprocket........... 137
Installing timing chain rails .......................................... 138
Installing rotor............................................................. 138
Adjusting crankshaft position sensor distance................. 138
Setting engine to top dead center.................................. 139
Installing piston .......................................................... 139
Installing cylinder head................................................ 140
Installing camshafts .................................................... 141
Installing timing chain tensioner ................................... 141
Checking valve clearance ............................................. 142
Adjusting valve clearance ............................................. 142
Installing spark plug .................................................... 143
Installing spacer and spring.......................................... 143
Installing clutch cover.................................................. 143
Mounting water pump cover.......................................... 144
Installing thermostat.................................................... 144