KTM 2011 690 SMC EU Repair Manual page 6

TABLE OF CONTENTS
16.4.32 Checking shift mechanism......................... 136
16.4.33 Preassembling shift shaft .......................... 136
16.4.34 Disassembling the main shaft .................... 137
16.4.35 Dismantling countershaft........................... 137
16.4.36 Checking the transmission ......................... 138
16.4.37 Assembling the main shaft......................... 139
16.4.38 Assembling countershaft ........................... 140
16.4.39 Checking the starter drive .......................... 141
16.4.40 Removing freewheel .................................. 141
16.4.41 Checking freewheel ................................... 142
16.4.42 Installing freewheel................................... 142
16.5 Engine assembly ........................................... 143
16.5.1 Installing transmission shafts..................... 143
16.5.2 Installing crankshaft and balancer shaft ...... 144
16.5.3 Installing left engine case.......................... 145
16.5.4 Installing oil pumps .................................. 145
16.5.5 Installing locking lever .............................. 146
16.5.6 Installing shift drum locating ..................... 146
16.5.7 Installing shift shaft .................................. 146
16.5.8 Installing starter drive ............................... 146
16.5.9 Installing primary gear............................... 147
16.5.10 Installing clutch cage ................................ 147
16.5.11 Installing crankshaft position sensor ........... 148
16.5.12 Installing timing chain and timing chain
sprocket................................................... 149
16.5.13 Installing timing chain rails ....................... 149
16.5.14 Installing rotor .......................................... 149
16.5.15 Adjusting crankshaft position sensor
distance................................................... 150
16.5.16 Setting engine to top dead center ............... 150
16.5.17 Installing piston........................................ 150
16.5.18 Installing cylinder head ............................. 152
16.5.19 Installing camshafts.................................. 152
16.5.20 Installing timing chain tensioner ................ 153
16.5.21 Checking valve clearance........................... 153
16.5.22 Adjusting valve clearance .......................... 154
16.5.23 Installing spark plug.................................. 155
16.5.24 Installing spacer and spring ....................... 155
16.5.25 Installing clutch cover ............................... 155
16.5.26 Mounting water pump cover ....................... 155
16.5.27 Installing thermostat ................................. 156
16.5.28 Installing the oil filter................................ 156
16.5.29 Installing gear position sensor .................... 156
16.5.30 Installing the spacer.................................. 157
16.5.31 Installing oil screens ................................. 157
16.5.32 Installing alternator cover .......................... 158
16.5.33 Installing starter motor .............................. 158
16.5.34 Installing valve cover................................. 159
16.5.35 Removing the engine from the engine
assembly stand......................................... 159
17 CLUTCH .................................................................. 160
17.1 Checking/rectifying the fluid level of the
hydraulic clutch............................................ 160
17.2 Changing the hydraulic clutch fluid ................ 160
18 WATER PUMP, COOLING SYSTEM ............................ 161
18.1 Draining the coolant ...................................... 161
18.2 Filling/bleeding the cooling system ................. 161
18.3 Checking the antifreeze and coolant level ........ 162
18.4 Checking the coolant level ............................. 163
19 LUBRICATION SYSTEM............................................ 164
19.1 Oil circuit..................................................... 164
19.2 Checking the engine oil level.......................... 164
19.3 Checking the engine oil pressure .................... 165
19.4 Changing the engine oil and filter, cleaning
the oil screens .............................................. 166
19.5 Draining the engine oil .................................. 166
19.6 Removing the oil filter ................................... 167
19.7 Installing the oil filter.................................... 167
19.8 Cleaning the oil screens................................. 168
19.9 Filling up with engine oil ............................... 169
19.10 Adding engine oil .......................................... 169
20 IGNITION SYSTEM................................................... 170
20.1 Alternator - checking the stator winding .......... 170
20.2 Checking the spark plug connector ................. 170
20.3 Ignition coil - checking the secondary
winding........................................................ 171
21 TECHNICAL DATA.................................................... 172
21.1 Engine ......................................................... 172
21.2 Engine tolerance, wear limits ......................... 172
21.3 Engine tightening torques .............................. 174
21.4 Capacities .................................................... 175
21.4.1 Engine oil ................................................ 175
21.4.2 Coolant .................................................... 175
21.4.3 Fuel ........................................................ 175
21.5 Chassis ........................................................ 175
21.6 Electrical system........................................... 176
21.7 Tires ............................................................ 176
21.8 Fork............................................................. 177
21.9 Shock absorber ............................................. 177
21.10 Chassis tightening torques ............................. 178
22 CLEANING/PROTECTIVE TREATMENT....................... 180
22.1 Cleaning the motorcycle ................................ 180
22.2 Checks and maintenance steps for winter
operation...................................................... 181
23 STORAGE ................................................................ 182
23.1 Storage ........................................................ 182
23.2 Preparing for use after storage........................ 182
24 SERVICE SCHEDULE ............................................... 183
24.1 Service schedule........................................... 183
25 WIRING DIAGRAM ................................................... 186
25.1 Page 01 of 10 .............................................. 186
25.2 Page 02 of 10 .............................................. 188
25.3 Page 03 of 10 .............................................. 190
25.4 Page 04 of 10 .............................................. 192
25.5 Page 05 of 10 .............................................. 194
25.6 Page 06 of 10 .............................................. 196
25.7 Page 07 of 10 .............................................. 198
25.8 Page 08 of 10 .............................................. 200
25.9 Page 09 of 10 .............................................. 202
25.10 Page 10 of 10 .............................................. 204
26 SUBSTANCES ......................................................... 206
27 AUXILIARY SUBSTANCES ........................................ 208
28 SPECIAL TOOLS ...................................................... 210
29 STANDARDS ........................................................... 222
INDEX ............................................................................ 223
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