Ktm 690 SM/ SMC/ SMR/ Duke Removal and Installation weld slag

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Filed Under (KTM) by admin on 04-03-2012

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1. Each bike varies with regard to welds and gussets. Review the photos first to get the idea of what needs to be done. 2. These photos may not be your exact model but depict the concept of what must be done. 3. Block the front tire securely before removing the top triple clamp so the tire cannot move at all. See photos. 4. Support the rear tire also, just enough to keep tension on the front tire so the forks stay tight. 5. Warning: Once the triple clamp is loose, the forks can roll away from the bike AND it happens very quickly . 6. The main triple clamp nut adjusts the tension on the steering head bearings. Make note of its tension before removing and do not over tighten the nut. It should be seated just enough to take the play out of the bearing.. 7. The top of the gauge/light cluster is mounted to the top triple clamp. You have to take out 4 self tapping Phillips head screws to remove the gauge pod. There is one connector on the back side of that and then it comes off. Then there are two bolts that need to come out with an 8mm wrench to free the top triple clamp. 8. Loosen the triple clamp pinch bolt under the main nut and forks pinch bolts and remove the top triple clamp, taking note of how tight the main nut is, so you can re-tighten it to the exact amount. Remove the tin bearing shroud (cover) and rubber seal making note of how the seal goes on, (lips face downward). 9. Grease your bearings while you have them exposed. (Keep the grease off the area where our frame bracket mounts!). 10. The goal is to allow the frame bracket to clamp cleanly and squarely around the upper half of the head tube. 11. Review your individual bike’s welding characteristics at the head tube. You’ll notice on the head tube there is a “groove” machined 360 degrees around the head tube. Everything in or above this groove must be clean of welds or slag. If this groove is visible all the way around and no welding slag has extended upward into or past this groove, then you’re installation should be easy. Any welds extending into or above this groove must be filed away, but without changing the clamping area diameter. DO NOT file away the paint on the clamping area if possible. Spend a little more time filing carefully and your bracket will stay tight. 12. Each bike seems to have not only different welds, but slightly different gussets. Evaluate your individual bike to determine the best fit. The bracket must clamp squarely and cleanly to the area just above that groove and yet SIT FLUSH all the way around the diameter of the head tube as per the photo in the lower right corner. Do not allow the bracket to protrude above the seal seating surface. Use a flashlight to see up under the bracket where it’s hitting if it’s not Flush. This bracket has clearance cut into it to clear the backbone of the frame

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