KTM Chassis 690 SMC Guide

690 SMC USA 2008
SPARE PARTS MANUAL: CHASSIS
ART.NO.: 3CF9775H4EN
ENGLISH

INDEX
690 SMC USA 2008
FRONT FORK, TRIPLE CLAMP
4x
FRONT FORK DISASSEMBLED
5x
HANDLEBAR, CONTROLS
6x
FRAME
7x
SIDE / CENTER STAND
9x
MONOSHOCK
10x
PRO LEVER LINKING
11x
SWING ARM
12x
EXHAUST SYSTEM
13x
AIR FILTER
14x
TANK, SEAT, COVER
15x
FUEL PUMP
17x
1

INDEX
690 SMC USA 2008
MASK, FENDERS
18x
DECAL
19x
FRONT WHEEL
20x
REAR WHEEL
21x
WIRING HARNESS
22x
BATTERY
23x
HAND BRAKE CYLINDER
24x
REAR BRAKE CONTROL
25x
BRAKE CALIPER FRONT
26x
BRAKE CALIPER REAR
27x
LIGHTING SYSTEM
28x
INSTRUMENTS / LOCK SYSTEM
29x
2

INDEX
690 SMC USA 2008
EVAPORATIVE CANISTER
30x
SPECIAL TOOLS
31x
ACCESSORIES KIT
32x x
x x x x
x
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical
specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local
conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing
certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations,
descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
© by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-
SPORTMOTORCYCLE AG, Mattighofen only.
3

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 14187D12 KTM 690 SMC '08 1
4 0025080353 COLLAR SCREW M8X35 TX 2
5 0025080303 COLLAR SCREW M8X30 TX 1
6 0912100356 AH SCREW DIN6912-M10X35 10.9 2
7 0025080406 HH COLLAR SCREW M8X40 TX40 8
8 0025080256 HH COLLAR SCREW M8X25 TX40 4
9 0912080303 AH SCREW DIN0912-M 8X30 4
32 7650113103301 BOT.TRIPLE CLAMP 32-34 OFFSET 1
33 76501033000 FORK TUBE L=237MM 08 1
34 7650113403301 TRIPLE CLAMP TOP 32-34 ADJUST. 1
38 59401038000 HANDLEBAR CLAMP 28MM 05 2
39 59401039042 HANDLEB.SUPP. D=28MM H=42MM 05 2
40 54801036000 STEER.HEAD SCREW M20X1,5 WS=27 1
41 54801036100 STE.HEAD SCR. M20X1,5 WS=27 SL 1
81 54201081100 TAPERED ROLLER BEARING CPL. 06 2
82 54601084100 O-RING SUPPORT W. SEALING LIP 1
84 54601184000 STEARING HEAD GASKET TOP 1
86 54201086000 STEERING HEAD COVER 1
90 0017060204 EJOT PT SCREW K60X20 ALU WS=6 2
91 59001092050 SPECIAL SCREW M6X12,5 WS=8 6
92 7650109400030 FORK PROTECT. L/S+R/S BLACK 08 1
93 7650109201030 FORK PROTECTOR CLAMP 1
94 0934080003 HEXAGON NUT DIN0934-M 8 2
087650111 / C087650111
* NEW PART X AS REQUIRED
4
FRONT FORK
,
TRIPLE CLAMP

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 48600536S2 AXLE CLAMP R/S CPL. 08 1
2 48600535S2 AXLE CLAMP L/S CPL. 08 1
3 91410058S SPRING D43.2 L465 5N/MM SET x
3 91410064S SPRING D43.2L465 5.2N/MM D5.25 x
3 91410065S SPRING D43.2L465 5.4N/MM D5.25 x
4 46810146 COPPER WASHER 12X16X1,5 2
6 48600036 SPACER 42X26,5X2,5 2
6 48600037 SPACER 42X26,5X5 2
6 48600038 SPACER 42X26,5X10 2
6 48600053 SPACER 42X26,5X1,5 2
7 48600558S SCREW CAP M51X1,5 CPL. 07 2
8 48600705S1 CARTRIDGE CPL. 08 2
9 48600484 OUTER TUBE L=500MM D=54/60 2
10 R14011 REPAIR-KIT GASKET 05 1
11 48600401S1 FORK OIL SAE5 5L 2005 1
12 T511 SILICONE GREASE F. DUST STRI 1
13 48600428 DU-BUSH D47XD49X20DDL02 2
14 48600429 DU-BUSH D48XD52X12DDL02 2
15 48600013 SUPPORT RING 50 X 57,6 X 1,5 2
16 48600347 OIL SEAL RING 48X57,8X9,5 03 2
17 48600070 LOCK WASHER SB58 2
18 48600400 DUST CAP D=48 58,4X11,8 2
087500131 / C087650131
* NEW PART X AS REQUIRED
5
FRONT FORK DISASSEMBLED

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 5480200120017 HANDLEBAR D=28 MM RENTHAL 796 1
4 76502010000 THROTTLE GRIP CPL. 08 1
5 63002021200 GRIPP SET 2K WITH OPEN END 1
6 75002091000 THROTTLE CABLE 07 1
7 58412040050 SUPPORT FOR MIRROR LC4 '98 2
8 61112040000 REVIEW MIRROR L/S 07 1
9 61112041000 REVIEW MIRROR R/S 07 1
10 60002030000 MASTER CYLINDER MAGURA D=10.5 1
11 60002044000 CLAMP MIRROR WITH CLAMP 1
12 0025060206 HH COLLAR SCREW M6X20 TX30 1
14 0965040123 FLAT HEAD SCREW DIN0965-M 4X12 2
15 50302033000 COVER FOR HYDR. CLUTCH '98 1
16 50302034000 RUBBER FOR RESERVOIR '98 1
17 50302032000 REP.SET PISTON MAGURA D=10.5 1
18 50302037000 PROTECT.CAP FOR LEVER PERCH'98 1
19 59002035000 SPRING FOR CLUTCH LEVER 03 1
20 60002031000 CLUTCH LEVER LONG CPL. 2003 1
21 50302038000 LEVER SCREW CPL. 125-200 '98 1
23 75032063000 CLUTCH PIPE SM 07 1
24 50302036200 OIL FOR HYD. CLUTCH 75ML 1
25 58411049100 CLUTCH SWITCH 03 1
40 76511070000 LIGHT SWITCH L/S 08 1
41 76511074000 START-EMERGENCY STOP SWITCH 08 1
42 6000207910030 HANDGUARD L/S+R/S CPL.BLACK 04 1
087650211 / C087650211
* NEW PART X AS REQUIRED
6
HANDLEBAR
,
CONTROLS

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 7650300100033 FRAME "EC08" BLACK MATT 08 1
2 7650300500001S ENGINE SUPPORT LEFT SIDE 08 1
3 7650300600001S ENGINE SUPPORT RIGHT SIDE 08 1
4 0035100249 AH-COLLAR SCREW M10X24 ISA45 4
5 75003015000 SPECIAL SCREW M10X115 ISK8 07 1
6 75003014000 SCREW 1
7 54630044000 COLLAR NUT M10 WS=13 2
8 76504067000 CHAIN SLID. GUARD 08 1
9 54310086100 SELF LOCKING NUT M10 CU WS=14 4
10 0025080206 HH COLLAR SCREW M8X20 TX40 1
16 7650303804401S FOOTREST BRACKET L/S 08 1
17 7650303904401S FOOTREST BRACKE R/S 08 1
18 0025080456 HH COLLAR SCREW M8X45 TX40 4
20 7650304800001S FOOT REST BRACKET REAR L/S 1
21 7650304900001S FOOT REST BRACKET REAR R/S 1
22 76503038050 HEEL PROTECTOR LS 08 1
23 76503039050 HEEL PROTECTOR RS 08 1
24 0025080166 HH COLLAR SCREW M8X16 TX40 4
26 0025080126 HH COLLAR SCREW M8X12 TX40 4
30 60003050000 FOOTREST CPL. L/S REAR 03 1
31 60003051000 FOOTREST CPL. R/S REAR 03 1
32 60003044000 BOLT FOR FOOTREST REAR 03 2
33 0799060003 TAB WASHER DIN6799-RS 6,0 2
34 60003052000 ENGAGE PANEL FOOTREST R/S 03 2
35 60003152000 ENGAGE PANEL FOOTREST L/S 03 2
39 76503040033 FOOTREST L/S+R/S CPL. 08 1
40 59003040250 FOOT PED L/S SILVER 02 1
41 59003041250 FOOT PED R/S SILVER 02 1
42 76503044000 BOLT FOR FOOT PED 08 2
43 54603041000 FOOTREST SPRING L/S & R/S 2
44 0125100003 WASHER DIN0125-A10,5 2
45 0094032253 PIN DIN0094-3,2X25 STEEL 2
50 76503083000 COVER FRAME L/S 1
51 76503084000 COVER FRAME R/S 1
52 69008021080 RANGE CHANGE METAL NUT M5 2
53 76503075000 SPREAD RIVET CPL. 6,2MM 1
087650310 / C087650310
* NEW PART X AS REQUIRED
7
FRAME

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
54 58605083014 SCREW M5X14 TORX 25 07 2
55 0770080020 O-RING 8X2 SILICONE 1
56 60038082000 ANGLE CONNECTOR LC8 03 1
57 76530087000 VENTILATION OIL SEPARATOR FOAM 1
087650310 / C087650310
* NEW PART X AS REQUIRED
8
FRAME

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 7650302300033 SIDE STAND L=275MM SMC 08 1
2 61003024000 SPRING L=116 MM 05 1
3 62503027100 SCREW F. SIDE STAND M10X31,2 1
4 76503028001 SPECIAL SCR. SIDE STAND SPRING 1
5 76503029000 MAGNET HOLDER 1
6 0025060126 HH COLLAR SCREW M6X12 TX30 1
7 76503026000 SIDE STAND BRACKET 08 1
8 0025080206 HH COLLAR SCREW M8X20 TX40 2
11 61011045000 SIDE STAND SENSOR 05 1
12 0084040123 CYL.HEAD SCREW DIN84A M4x12 2
13 76511045050 HOLDER FOR SIDESTAND SWITCH 08 1
14 0985040003 SELF LOCKING NUT DIN0985-M 4 2
15 0016050121 SCREW FOR PLASTIC 50X12 1
087650360 / C087650360
* NEW PART X AS REQUIRED
9
SIDE
/
CENTER STAND

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 15187D12 MONOSHOCK 690 SMC 08 1
2 46180682S1 SHOCK ABS. UPPER CPL. 08 1
3 46180519 LOCK RING D=55 1
4 46180661S MEMBRANE COVER CPL. 08 1
5 46180518 MEMBRANE D52 1
6 50180095 BLEED PLUG R 1/8 1
7 76504016000 CYL. SCREW M10X1,25 L=53 2
10 46180533S1 DCC-COMPR.DAMP.CONTROL HS95 1
11 46810010 CIRCLIP 49X1,5 1
20 46180654S2 SHOCK ABS. BOTTOM CPL. SMC 1
21 R15006 REPAIR KIT BEARINGS 07 1
30 46180445 COUNTERNUT 1
31 46180444 ADJUSTING NUT 1
32 91110004S SPRING 220MM 80N/MM (61) x
32 91110005S SPRING 220MM 85N/MM (61) x
32 91110014S SPRING 220MM 90N/MM (61) x
33 46180396 SPRING RETAINER H=15 D=28 1
40 R15004 REPAIR KIT GASKET 05 1
41 50180342S1 SHOCK ABSORBER FLUID 5 LT '03 1
087650410 / C087650411
* NEW PART X AS REQUIRED
10
MONOSHOCK

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
2 54603097000 NEEDLE BUSH HK 2016 4
3 54603081000 BUSHING SLEEVE 15 X 20 X 48 2
4 54603090010 STEEL WASHER 15,2X19X0,1 x
4 54603090020 STEEL WASHER 15,2X19X0,2 x
4 54603090030 STEEL WASHER 15,2X19X0,3 x
5 0760253270 SHAFT SEAL RING 25X32X7 4
6 76504089000 BUCKET FOR SHAFT SEAL RING 4
7 76504084000 PULL ROD ANCHOR BOLT 1
8 56503195100 NEEDLE BEARING HK 1816 4
9 0760182442 SHAFT SEAL RING 18X24X4 2
20 7650408104401 CANTILEVER CPL. 07 1
21 7650408304401 PULL ROD CPL. 08 1
30 76504082044 BOLT CPL. M14X1,5 2
31 0025080166S HH COLLAR SCREW M8X16 TX40 2
32 54603015000 SELF LOCKING NUT M14X1,5 WS=19 2
33 54403135000 PLASTIC CAP SFL10 4
34 0021080003 WASHER DIN9021-A 8,4 2
35 36003014000 LOCK WASHER 8MM 2
087650460 / C087650460
* NEW PART X AS REQUIRED
11
PRO LEVER LINKING

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 76504030044 SWING ARM CPL. 08 1
2 76504034000 BUCKET FOR SHAFT SEAL RING 4
3 0760253270 SHAFT SEAL RING 25X32X7 4
4 59404032000 BEARING SLEEVE 17X22X38,7 03 2
5 59004031100 NEEDLE BEARING HK2212V 4
6 54603036000 STOP DISK 22,2X31,7X1 2
7 76504066000 CHAIN SLIDING GUARD 07 1
8 77304066050 BUSHING F. CHAIN SLIDING PR.07 2
9 0025060106 HH COLLAR SCREW M6X10 TX30 2
10 76504042000 BRAKE LINE GUIDE 08 1
11 0009050103 SPECIAL SCREW M 5,0X10 2
12 76504060000 CHAIN GUARD 08 1
13 0081500181 SCREW FOR PLASTIC D=5X18 2
14 0025060126 HH COLLAR SCREW M6X12 TX30 1
15 0025060166 HH COLLAR SCREW M6X16 TX30 1
17 77304070000 CHAIN GUIDE REAR CPL. 07 1
18 77304070030 INSERTION NUT F. CHAIN GUIDE 1
19 0025060456 HH COLLAR SCREW M6X45 TX30 1
20 0025060206 HH COLLAR SCREW M6X20 TX30 1
21 75304037044 SWINGARM BOLT L=246 M12X1,5 1
22 76504038000 SPECIAL SCREW M12X40 SW19 2
23 58414030000 HH COLLAR NUT M10X1,25 WS=13 2
24 50304040100 SCREW M10X1,25X50 WS=10 2
25 58404041000 CLOSING COVER SWINGARM SM 03 4
087650490 / C087650490
* NEW PART X AS REQUIRED
12
SWING ARM

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 76505007000 EXHAUST MANIFOLD 08 1
2 51010086100 SELF LOCKING NUT M 8 CU 2
3 61005009000 SPACER BUSH. 8,5X15X7,5 05 1
4 61005005000 EXHAUST GASKET 05 1
5 75041090000 LAMBDA SENSOR 07 1
6 76505090010 HEAT SHIELD EXHAUST MAINFOLD 1
7 58605083010 SCREW TORX M5X10 05 4
8 76505090020 HEAT SHIELD SILENCER 1
9 58605005000 GRAPHIT RING 55X50X25 05 1
10 76505051000 CLAMP FOR SILENCER 57,4MM 08 1
11 76505082000 SILENCER USA 08 1
12 69008021080 RANGE CHANGE METAL NUT M5 4
13 0025080356 HH COLLAR SCREW M8X35 TX40 2
14 58405050065 COLLAR BUSH 8,5X12X23,5X10 4
15 54305068100 DAMP. COMPONENT SILICONE GREY 2
16 49109481052 HH COLLAR SCREW M 8X16 WS=13 2
17 76505084000 HOLDER SILENCER 1
18 0797050000 TOOTH LOCK WASHER DIN6797-J 4
087650510 / C087650511
* NEW PART X AS REQUIRED
13
EXHAUST SYSTEM

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 76506002000 FILTER BOX-TOP PART 08 1
2 0025060126 HH COLLAR SCREW M6X12 TX30 2
3 76506015000 AIRFILTER PAPER 200X120 1
4 0025060126 HH COLLAR SCREW M6X12 TX30 4
5 43205062100 RUBBER GROMMET 20X15-M6X10 (1) 4
6 76506003044 FILTER BOX WITH INTAKE FLANGE 1
7 76506026000 INTAKE FLANGE 08 1
8 51006027000 HOSE CLAMP 50-70MM 1
087650610 / C087650610
* NEW PART X AS REQUIRED
14
AIR FILTER

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 7650701300030 FUEL TANK 08 1
2 76507065000 RUBBER BEAR. BOX 12X24 L=24,5 2
3 76507060000 BEARING BUSHING UP 2
4 76507061000 BEARING BUSHING DOWN 1
5 76507028000 TANK-RETAINING PLATE R/S 08 1
6 76507027000 TANK-RETAINING PLATE L/S 08 1
7 0025080166 HH COLLAR SCREW M8X16 TX40 6
8 54806008052 RIVET 3,2MM ALU 03 4
9 54806008050 QUICK RELEASE-SPRING HANGER 2
10 76507050000 SEAT LOCK 1
11 0738060181 COU.SUNK SCR. AH ISO7380 M6X18 2
12 76507008000 TANK PLUG 08 1
13 40011166100 KEY BLANK LC4/DUKE/LC8 x
14 58605083014 SCREW M5X14 TORX 25 07 3
15 76507008050 CLOSURE FLANGE 1
16 0770050030 O-RING 50,00X3,00 VITON 1
17 76506010000 SPLASHBACK 08 1
18 72210079000 BUCKET 2
19 0025060106 HH COLLAR SCREW M6X10 TX30 6
20 76507053000 CLAMP F. CABLE SEAT LOCK 1
21 76507066000 RUBB.BEAR.BOX 12x24x35 L=24,5 2
30 76507040000 SEAT 08 1
31 76507040050 SEAT COVER 08 1
32 75007046010 SEAT RUBBER 10 MM 6
33 76507048000 BRACKET F. SEAT 1
34 0023060123 COLLAR SCREW M6X12 TX 2
35 58407011100 SCREW FOR SEAT M6X11,5/8 1
40 7650805000004 SPOILER L/S ORANGE 2008 1
41 7650805100004 SPOILER R/S ORANGE 2008 1
42 7650804100030 SIDE COVER L/S BLACK 08 1
43 7650804200030 SIDE COVER R/S BLACK 08 1
44 54806008051 QUICK RELEASE-NIPPLE 03 2
46 54603048100 RANGE CHANGE METAL NUT M6 4
47 76508043150 COLLAR BUSHING 2
48 76508043050 COLLAR BUSHING 2
49 0025060166 HH COLLAR SCREW M6X16 TX30 2
087650710 / C087650710
* NEW PART X AS REQUIRED
15
TANK
,
SEAT
,
COVER

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
50 0025060126 HH COLLAR SCREW M6X12 TX30 2
51 0025080306 HH COLLAR SCREW M8X30 TX40 2
52 43205062100 RUBBER GROMMET 20X15-M6X10 (1) 2
ONLY FOR USA
087650710 / C087650710
* NEW PART X AS REQUIRED
16
TANK
,
SEAT
,
COVER

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 75007089000 SEALINGS KIT 1
2 75007090000 FILTER KIT 1
3 75007088011 FUEL PUMP WITH FLANGE CPL. 1
4 75007088012 PRESSURE REGULATOR CPL. 07 1
5 75007092000 HYDRAULIC CONNECTOR CPL. 1
7 00050153706 VARIABLE ONE-EAR CLAMP 15,3MM 2
8 75007116060 FUEL HOSE WITH CLUTCH 1
9 58507012000 O-RING VITON F. PLUG CPC 05 1
10 75007016050 FUEL HOSE WITH CLUTCH 1
20 0025050166 HH COLLAR SCREW M5X16 TX30 8
21 49007439000 CLAMP RSGU 15/12 1
22 0912040123 * AH SCREW DIN0912-M 4X12 1
087650730 / C087650730
* NEW PART X AS REQUIRED
17
FUEL PUMP

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 7650800100004 HEADLIGHT MASK 08 1
2 0025050126 HH COLLAR SCREW M5x12 TX30 2
3 54603048200 RANGE CHANGE METAL NUT M5 2
4 7730821000004 FENDER FRONT SMR 08 1
5 62508009000 COLLAR BUSHING 7,2X10X15X8,5 4
6 0024060206 HH COLLAR SCREW M6X20 TX30 4
7 60012080000 SIDE REFLECTOR YELLOW 03 2
ONLY FOR USA+AUS+UK
8 76513025000 BRAKE HOSE GUIDE 1
10 7650801300004 REAR FENDER 1
11 0025060126 HH COLLAR SCREW M6X12 TX30 6
14 76512008000 HAND GRIP L/S 1
15 76512009000 HAND GRIP R/S 1
16 0019080756 COUNTERSUNK SCREW ISA45 M8X75 4
17 76508116000 NUMBER PLATE CARRIER TOP 08 1
18 0025080256 HH COLLAR SCREW M8X25 TX40 4
20 0017060203 EJOT PT SCREW K60X20 WS=6 1
21 0017060303 SPECIAL SCREW T60 6X30 WS=6 2
22 76514064000 COVER 08 1
23 58214069051 RUBBER GROMMET 16X10,8X3 02 1
24 75014010050 COLLAR BUSHING 6,1X8,1X14X8 07 1
27 76508043050 COLLAR BUSHING 6
30 60012081200 LICENCE FITTING 06 1
31 0024060156 HH COLLAR SCREW M6X15 TX30 5
32 0021060003 WASHER DIN9021-A 6,4 4
33 0985060003 SELF LOCK. NUT DIN0985-M 6 4
34 0966050163 OVAL HEAD SCREW DIN0966-M 5X16 2
35 40006006000 WASHER 6MM 2
36 0125050003 WASHER DIN0125-A 5,3 2
37 0985050003 SELF LOCKING NUT DIN0985-M 5 2
38 58412080000 REFLECTOR RED LC4 '98 1
39 58412080050 BRACKET FOR REFLECTOR 1
40 62512081000 BRACKET SIDE REFLECTOR 06 1
41 16512180100 SIDE REFLECTOR RED REAR 2
ONLY FOR USA
087650813 / C087650813
* NEW PART X AS REQUIRED
18
MASK
,
FENDERS

690 SMC USA 2008
FIG PART NUMBER DESCRIPTION QTY
1 76508099100 DECAL SET 690 SMC 2008 1
087650831 / C087650831
* NEW PART X AS REQUIRED
19
DECAL