User manual KTM 690 SMC UK 2008

[. . . ] 3211245en DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! 1 Enter the serial numbers of your vehicle below. 17) The owner's manual corresponded to the latest state of this series at the time of printing. [. . . ] 168) Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. MAINTENANCE WORK ON CHASSIS AND ENGINE Lean the motorcycle on the side stand. Push the chain upward at a distance chain tension . 72 from the chain sliding guard and determine the Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension Distance to chain sliding guard » 5 mm (0. 2 in) 30 mm (1. 18 in) If the chain tension does not meet specifications: Adjust the chain tension. 72) 100249-10 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension. If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. MAINTENANCE WORK ON CHASSIS AND ENGINE Lean the motorcycle on the side stand. Loosen nut Loosen nuts Specification Chain tension 5 mm (0. 2 in) Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . left and right. 73 Adjust the chain tension by turning the adjusting screws Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. Tighten nuts Tighten nut Specification Nut, rear wheel spindle M25x1. 5 90 Nm (66. 4 lbf ft) . are fitted correctly on the adjusting screws . Make sure that the chain adjusters 600597-10 Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters can be turned by 180°. MAINTENANCE WORK ON CHASSIS AND ENGINE Checking rear sprocket / engine sprocket for wear Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: Replace rear sprocket / engine sprocket. 74 Info The engine sprocket, rear sprocket and chain should always be replaced together. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. Check chain guides for tightness and wear. 100132-10 MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain wear Shift into neutral, pull the lower chain section with the specified weight Specification Weight of chain wear measurement Measure the distance 15 kg (33 lb. ) . 75 of 18 chain links in the lower chain section. Info A » Chain wear is not always even, so you should repeat this measurement at different chain positions. [. . . ] 3. 15 in) 400 mm (15. 75 in) 161 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Spoke nipple, front wheel Spoke nipple, rear wheel Remaining screws, chassis Screw, exhaust heat shield Screw, electrical holder Screw, footbrake pedal foothold Screw, fuel pump Screw, fuel level indicator Screw, headlight mask Screw, side stand switch Screw, side cover Screw, seat lock Screw, starter cable on starter Nut, foot brake cylinder screw Remaining nuts, chassis Remaining screws on fuel tank Remaining screws, chassis Screw, brake fluid reservoir of rear brake Screw, rear brake disc Screw, front brake disc Screw, license plate holder, bottom Screw, ball joint of push rod on footbrake cylinder Screw, radiator bracket M4, 5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 4 Nm (3 lbf ft) 4 Nm (3 lbf ft) 4 Nm (3 lbf ft) 8 Nm (5. 9 lbf ft) 3 Nm (2. 2 lbf ft) 6 Nm (4. 4 lbf ft) 6 Nm (4. 4 lbf ft) 3 Nm (2. 2 lbf ft) 5 Nm (3. 7 lbf ft) 3 Nm (2. 2 lbf ft) 2 Nm (1. 5 lbf ft) 3 Nm (2. 2 lbf ft) 3 Nm (2. 2 lbf ft) 10 Nm (7. 4 lbf ft) 15 Nm (11. 1 lbf ft) 6 Nm (4. 4 lbf ft) 10 Nm (7. 4 lbf ft) 5 Nm (3. 7 lbf ft) 14 Nm (10. 3 lbf ft) 14 Nm (10. 3 lbf ft) 8 Nm (5. 9 lbf ft) 10 Nm (7. 4 lbf ft) 5 Nm (3. 7 lbf ft) Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 222 Loctite® 243TM 162 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, magnetic holder on side stand Screw, voltage regulator/rectifier Screw, SLS valve Screw, ignition lock Nut, rear sprocket screw Nut, manifold on cylinder head Remaining nuts, chassis Remaining screws, chassis Screw, exhaust clamp on main silencer Screw, main silencer holder Screw, main silencer holder on fuel tank Screw, rear footrest bracket Screw, front footrest bracket Screw, spring holder on side stand bracket Screw, top triple clamp Screw, bottom triple clamp Screw, fork stub Screw, steering stem Screw, handrail Screw, license plate holder, top Screw, fuel tank, top Screw, fuel tank, bottom Screw, handlebar clamp M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 10 Nm (7. 4 lbf ft) 8 Nm (5. 9 lbf ft) 4 Nm (3 lbf ft) 10 Nm (7. 4 lbf ft) 35 Nm (25. 8 lbf ft) 25 Nm (18. 4 lbf ft) 30 Nm (22. 1 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 17 Nm (12. 5 lbf ft) 12 Nm (8. 9 lbf ft) 15 Nm (11. 1 lbf ft) 20 Nm (14. 8 lbf ft) 20 Nm (14. 8 lbf ft) 20 Nm (14. 8 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 20 Nm (14. 8 lbf ft) Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Copper paste Loctite® 243TM 163 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, side stand bracket Screw, connection lever on frame Remaining nuts, chassis Remaining screws, chassis Screw, front brake caliper Engine carrying screw Screw, top shock absorber Screw, bottom shock absorber Screw, foot brake pedal Screw, handlebar support Screw, engine bearer on frame Screw, side stand Lambda probe Screw, swingarm pivot Nut, linkage lever to rocker arm Nut, linkage lever on swingarm Screw, top steering head Screw, bottom steering head Screw, front wheel spindle Nut, rear wheel spindle M8 M8 M10 M10 M10x1. 25 M10 M10 M10 M10LH M10 M10 M10 M12x1. 25 M12x1. 75 M14x1. 5 M14x1. 5 M20x1. 5 M20x1. 5 M24x1. 5 M25x1. 5 25 Nm (18. 4 lbf ft) 30 Nm (22. 1 lbf ft) 50 Nm (36. 9 lbf ft) 45 Nm (33. 2 lbf ft) 45 Nm (33. 2 lbf ft) 45 Nm (33. 2 lbf ft) 45 Nm (33. 2 lbf ft) 45 Nm (33. 2 lbf ft) 25 Nm (18. 4 lbf ft) 40 Nm (29. 5 lbf ft) 45 Nm (33. 2 lbf ft) 35 Nm (25. 8 lbf ft) 24. 5 Nm (18. 07 lbf ft) 80 Nm (59 lbf ft) 100 Nm (73. 8 lbf ft) 100 Nm (73. 8 lbf ft) 10 Nm (7. 4 lbf ft) 60 Nm (44. 3 lbf ft) 40 Nm (29. 5 lbf ft) 90 Nm (66. 4 lbf ft) Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM Loctite® 243TM 164 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) according to DIN EN 228 (ROZ 95 / RON 95 / PON 91) 165 Brake fluid DOT 4 / DOT 5. 1 according to DOT Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® Brake Fluid DOT 5. 1 Coolant Specification Use only suitable coolant (even in countries with high temperatures). 49 °F) 50 % Anti-corrosion/antifreeze 50 % distilled water SUBSTANCES Coolant (mixed ready to use) Antifreeze Supplier Motorex® Anti Freeze 40 °C ( 40 °F) 166 Hydraulic fluid (15) according to ISO VG (15) Specification Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. Supplier Motorex® Hydraulic Fluid 75 Engine oil (SAE 10W/60) according to JASO T903 MA ( SAE ( P. [. . . ]