KTM 2011 690 SMC EU Repair Manual page 5

TABLE OF CONTENTS
12.7.8 Checking the chain, rear sprocket, engine
sprocket, and chain guide............................ 75
12.7.9 Cleaning the chain ...................................... 77
12.7.10 Checking the rear hub rubber dampers.......... 77
13 WIRING HARNESS, BATTERY..................................... 79
13.1 Removing the battery ...................................... 79
13.2 Installing the battery ....................................... 79
13.3 Disconnecting the battery ................................ 79
13.4 Connecting the battery .................................... 80
13.5 Recharging the battery .................................... 80
13.6 Checking the charging voltage .......................... 81
13.7 Changing the main fuse ................................... 82
13.8 Changing fuses of individual power
consumers...................................................... 82
13.9 Adjusting the engine characteristic ................... 83
14 BRAKE SYSTEM ........................................................ 85
14.1 Checking the front brake linings ....................... 85
14.2 Changing the brake linings of the front brake..... 85
14.3 Adjusting the basic position of the hand brake
lever .............................................................. 86
14.4 Checking the front brake fluid level .................. 86
14.5 Adding front brake fluid................................... 87
14.6 Changing the front brake fluid .......................... 88
14.7 Checking the rear brake linings ........................ 88
14.8 Changing the rear brake linings ........................ 89
14.9 Checking the free travel of foot brake lever ........ 90
14.10 Adjusting the basic position of the foot brake
lever .............................................................. 91
14.11 Checking rear brake fluid level ......................... 91
14.12 Adding rear brake fluid .................................... 92
14.13 Changing the rear brake fluid ........................... 92
15 LIGHTING SYSTEM, INSTRUMENTS ........................... 94
15.1 Combination instrument .................................. 94
15.1.1 Setting kilometers or miles .......................... 94
15.1.2 Setting the clock ........................................ 94
15.1.3 Setting/resetting display TRIP 1 ................... 94
15.1.4 Setting/resetting display TRIP 2 ................... 94
15.1.5 Setting the wheel circumference .................. 95
15.2 Checking the headlight setting ......................... 96
15.3 Adjusting the headlight range........................... 96
15.4 Removing the headlight mask with the
headlight........................................................ 96
15.5 Installing the headlight mask with the
headlight........................................................ 97
15.6 Changing the parking light bulb........................ 97
15.7 Changing the headlight bulb ............................ 98
15.8 Changing the turn signal bulb .......................... 99
16 ENGINE .................................................................. 100
16.1 Removing the engine..................................... 100
16.2 Installing the engine...................................... 102
16.3 Engine disassembly....................................... 106
16.3.1 Clamping the engine into the engine
assembly stand......................................... 106
16.3.2 Draining the engine oil .............................. 106
16.3.3 Removing starter motor ............................. 106
16.3.4 Removing valve cover ................................ 107
16.3.5 Removing the alternator cover .................... 107
16.3.6 Removing spacer ...................................... 107
16.3.7 Removing gear position sensor ................... 107
16.3.8 Removing oil filter .................................... 108
16.3.9 Removing thermostat ................................ 108
16.3.10 Setting engine to ignition top dead center ... 108
16.3.11 Removing water pump wheel...................... 109
16.3.12 Removing clutch cover .............................. 109
16.3.13 Removing spacer and spring ...................... 109
16.3.14 Removing spark plug................................. 110
16.3.15 Removing timing chain tensioner................ 110
16.3.16 Removing camshafts ................................. 110
16.3.17 Removing cylinder head ............................ 110
16.3.18 Removing piston ....................................... 111
16.3.19 Removing rotor ......................................... 111
16.3.20 Removing timing chain rails....................... 112
16.3.21 Removing timing chain and timing chain
sprocket................................................... 112
16.3.22 Removing crankshaft position sensor .......... 112
16.3.23 Removing clutch cage ............................... 113
16.3.24 Removing primary gear .............................. 114
16.3.25 Removing starter drive............................... 114
16.3.26 Removing shift shaft ................................. 114
16.3.27 Removing shift drum locating..................... 114
16.3.28 Removing locking lever.............................. 115
16.3.29 Removing oil pumps.................................. 115
16.3.30 Removing left engine case ......................... 115
16.3.31 Removing crankshaft and balancer shaft ..... 116
16.3.32 Removing transmission shafts .................... 116
16.4 Work on individual parts ................................ 117
16.4.1 Work on the right section of the engine
case ........................................................ 117
16.4.2 Work on the left section of the engine
case ........................................................ 119
16.4.3 Work on the clutch cover ........................... 120
16.4.4 Removing crankshaft bearing inner ring ...... 121
16.4.5 Removing balancer shaft drive wheel .......... 121
16.4.6 Changing the connecting rod, conrod
bearing, and crank pin .............................. 121
16.4.7 Checking crankshaft run-out at bearing
pin .......................................................... 123
16.4.8 Installing balancer shaft drive wheel ........... 123
16.4.9 Installing crankshaft bearing inner ring ....... 123
16.4.10 Measuring axial clearance of crankshaft
and balancer shaft .................................... 124
16.4.11 Cylinder - Nikasil
16.4.12 Checking/measuring the cylinder ................ 125
16.4.13 Checking/measuring the piston................... 125
16.4.14 Checking piston ring end gap ..................... 126
16.4.15 Checking piston/cylinder mounting
clearance ................................................. 126
16.4.16 Checking oil pumps for wear ...................... 127
16.4.17 Replacing autodecompressor...................... 127
16.4.18 Preparing timing chain tensioner for
installation ............................................... 128
16.4.19 Checking timing assembly ......................... 128
16.4.20 Removing rocker arm ................................ 129
16.4.21 Changing camshaft bearing........................ 129
16.4.22 Removing valves ....................................... 130
16.4.23 Checking valves ........................................ 130
16.4.24 Checking valve springs .............................. 131
16.4.25 Checking valve spring retainer.................... 131
16.4.26 Checking cylinder head ............................. 131
16.4.27 Installing valves ........................................ 132
16.4.28 Installing rocker arm ................................. 133
16.4.29 Disassembling the antihopping clutch......... 133
16.4.30 Checking the clutch .................................. 133
16.4.31 Preassembling the antihopping clutch......... 135
coating ......................... 124
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