Ktm 690 Smc 2010 Workshop Repair Service Manual
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
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 the compression damping of the 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 46
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
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 82
Combination instrument – setting the wheel
circumference 83
Checking the headlight setting 83
Adjusting the headlight range 84
Removing the headlight mask with the headlight 84
Installing the headlight mask with the headlight 84
Changing the parking light bulb 85
Changing the headlight bulb 86
Changing the flasher bulb 86
30/ENGINE 87
Removing the engine 87
Installing the engine 89
30/DISASSEMBLING THE ENGINE 93
Clamping engine into engine work stand 93
Draining the engine oil 93
Removing starter motor 93
Removing valve cover 93
Removing the alternator cover 94
Removing spacer 94
Removing gear position sensor 94
Removing oil filter 94
Removing thermostat 95
Setting engine to ignition top dead center 95
Removing water pump wheel 95
Removing clutch cover 96
Removing spacer and spring 96
Removing spark plug 96
Removing timing chain tensioner 97
Removing camshafts 97
Removing cylinder head 97
Removing piston 97
Removing rotor 98
Removing timing chain rails 98
Removing timing chain and timing chain sprocket 99
Removing crankshaft position sensor 99
Removing clutch cage 99
Removing primary gear 101
Removing starter drive 101
Removing shift shaft 101
Removing shift drum locating 101
Removing locking lever 102
Removing oil pumps 102
Removing left engine case 102
Removing crankshaft and balancer shaft 103
Removing transmission shafts 103
30/ENGINE – WORK ON INDIVIDUAL PARTS 105
Work on the right section of the engine case 105
Work on the left section of the engine case 106
Work on the clutch cover 108
Removing crankshaft bearing inner ring 108
Removing balancer shaft drive wheel 108
Changing the conrod bearing 108
Checking crankshaft run-out at bearing pin 110
Installing balancer shaft drive wheel 110
Installing crankshaft bearing inner ring 110
Measuring axial clearance of crankshaft and balancer
shaft 111
Cylinder – Nikasil® coating 111
Checking/measuring the cylinder 112
Checking/measuring the piston 112
Checking piston ring end gap 113
Checking piston/cylinder mounting clearance 114
Checking oil pumps for wear 114
Replacing autodecompressor 114
Preparing timing chain tensioner for installation 115
Checking timing assembly 116
Removing rocker arm 116
Changing camshaft bearing 116
Removing valves 117
Checking valves 118
Checking valve springs 118
Checking valve spring retainer 118
Checking cylinder head 118
Installing valves 119
Installing rocker arm 120
Dismantling antihopping clutch 120
Checking the clutch 121
Preassembling antihopping clutch 122
Checking shift mechanism 123
Preassembling shift shaft 123
Disassembling the main shaft 124
Dismantling countershaft 124
Checking the transmission 125
Assembling the main shaft 126
Assembling countershaft 127
Checking electric starter drive 128
Removing freewheel 128
Checking freewheel 129
Installing freewheel 129
30/ASSEMBLING THE ENGINE 131
Installing transmission shafts 131
Installing crankshaft and balancer shaft 132
Installing left engine case 132
Installing oil pumps 133
Installing locking lever 133
Installing shift drum locating 133
Installing shift shaft 134
Installing starter drive 134
Installing primary gear 134
Installing clutch cage 135
Installing crankshaft position sensor 136
Installing timing chain and timing chain sprocket 136
Installing timing chain rails 137
Installing rotor 137
Adjusting crankshaft position sensor distance 137
Setting engine to top dead center 138
Installing piston 138
Installing cylinder head 139
Installing camshafts 140
Installing timing chain tensioner 140
Checking valve clearance 141
Adjusting valve clearance 141
Installing spark plug 142
Installing spacer and spring 142
Installing clutch cover 142
Mounting water pump cover 143
Installing thermostat 143
CONTENTS 4
Installing the oil filter 143
Installing gear position sensor 144
Installing the spacer 144
Installing oil screens 145
Installing alternator cover 145
Installing starter motor 146
Installing valve cover 146
Taking engine off universal mounting rack 146
32/CLUTCH 147
Checking/rectifying the fluid level of the hydraulic
clutch 147
35/WATER PUMP, COOLING SYSTEM 148
Draining the coolant 148
Filling the cooling system 148
Checking the antifreeze and coolant level 149
Checking the coolant level 150
38/LUBRICATION SYSTEM 151
Oil circuit 151
Checking the engine oil level 151
Checking the engine oil pressure 152
Changing the engine oil and filter, cleaning the oil
screens 153
Draining the engine oil 153
Removing the oil filter 154
Installing the oil filter 154
Cleaning the oil screens 155
Filling up with engine oil 156
Adding engine oil 156
39/IGNITION SYSTEM 157
Alternator – checking the stator winding 157
Checking the spark plug connector 157
Ignition coil – checking the secondary winding 158
41/THROTTLE VALVE BODY 159
Checking the basic setting of the motor drive 159
Adjusting the basic setting of the motor drive 160
Flashing the EFI control unit and/or the EPT control
unit 163
Requesting the enabling code 164
Coding the EFI control unit and/or EPT control unit 165
TECHNICAL DATA – ENGINE 167
Capacity – engine oil 167
Capacity – coolant 167
TECHNICAL DATA – TOLERANCE, WEAR LIMITS OF
ENGINE 168
TECHNICAL DATA – ENGINE TIGHTENING TORQUES 170
TECHNICAL DATA – CHASSIS 172
Lighting equipment 172
Capacity – fuel 173
TECHNICAL DATA – FORK 174
TECHNICAL DATA – SHOCK ABSORBER 175
TECHNICAL DATA – CHASSIS TIGHTENING TORQUES 176
CLEANING/PROTECTIVE TREATMENT 178
Cleaning the motorcycle 178
Protective treatment for winter operation 179
STORAGE 180
Storage 180
Putting into operation after storage 180
SERVICE SCHEDULE 181
Service schedule 181
WIRING DIAGRAM 182
SUBSTANCES 202
AUXILIARY SUBSTANCES 204
SPECIAL TOOLS 206
STANDARDS 218
INDEX 219
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
Guillermo Axton –
I had no problem downloading as my biggest headache is the speed of which my local service sometimes handicaps things. The entire beauty of this rests with your own ability to print out and edit what you need for the project or projects at hand while not being concerned about ruining a book or hard copy manual with greasy hands and if you do….. print out again. I would also suggest that before doing anything make a back-up copy of everything to another drive or memory stick.