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ASSEMBLING THE ENGINE

Repair manual KTM 690 LC4

Art.-No. 3.206.045-E

MOUNTING THE TRANSMISSION SHAFTS, ASSEMBLING THE ENGINE CASE  . . . . .6-2
MOUNTING THE OIL PUMPS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
MOUNTING THE SHIFT MECHANISM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
MOUNTING THE STARTER DRIVE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
MOUNTING THE CLUTCH AND PRIMARY PINION  . . . . . . . . . . . . . . . . . . . . . . . .6-7
MOUNTING THE TIMING CHAIN PINION AND THE TIMING CHAIN . . . . . . . . . . . . .6-9
MOUNTING THE ROTORS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
MOUNTING THE PISTON, CYLINDER AND CYLINDER HEAD  . . . . . . . . . . . . . . . .6-10
MOVING THE ENGINE TO TDC  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
MOUNTING THE CAMSHAFT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
MOUNTING THE CHAIN TENSIONER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
RIGHT SIDE OF THE ENGINE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
LEFT SIDE OF THE ENGINE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

INDEX

6-1

6

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Summary of Contents for 690 LC4 2007

Page 1: ...690 LC4 REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE R PARATION MANUAL DE REPARACI N ART NR 3 206 045 E REPAIRMANUAL2007...

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Page 3: ...REPAIRMANUAL2007 690 LC4 KTM Group Partner...

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Page 5: ...AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL INJECTION 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 CHASSIS 11 TECHNICAL SPECIFICATIONS 12 PER...

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Page 7: ...EXPLANATION UPDATING Edition 01 2007 3 206 045 E Repair Manual 690 LC4 Basicversion Modelyear 2007 1 2007...

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Page 9: ...TS OUT USEFUL TIPS Use only ORIGINAL KTM SPARE PARTS when replacing parts The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and prof...

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Page 11: ...missing technical data or torques inaccurate or incorrect translations or wording etc please enter the error s in the table below and fax the completed form to us at 0043 7742 6000 5349 NOTE to table...

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Page 13: ...GENERAL INFORMATION Repair manual KTM 690 LC4 Art No 3 206 045 E SPECIAL TOOLS CHASSIS 2 1 SPECIAL TOOLS ENGINE 2 2 CHANGING THE ENGINE OIL SEE OWNER S MANUAL INDEX 2 1 2...

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Page 15: ...o 3 206 045 E SPECIALTOOLS CHASSIS FIG PART NO DESCRIPTION 1 625 29 055 000 Assembly stand 2 750 29 034 000 Adjusting nut for swingarm bearing 3 750 29 036 000 Assembly stand attachment 4 750 29 055 0...

Page 16: ...g mounting tool 18 750 29 021 000 Puller for primary gear 19 750 29 033 000 Mounting screws for Anti hopping clutch 20 750 29 035 000 Mounting tool for piston pin retainer 21 750 29 047 000 Crankshaft...

Page 17: ...2 4 Repair manual KTM 690 LC4 Art No 3 206 045 E 1 5 6 8 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 2 3 4...

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Page 19: ...TO TDC 4 4 REMOVING THE CYLINDER HEAD AND PISTON 4 5 REMOVING THE ROTOR 4 7 REMOVING THE TIMING CHAIN AND TIMING CHAIN PINION 4 7 REMOVING THE CLUTCH AND PRIMARY PINION 4 8 REMOVING THE STARTER DRIVE...

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Page 21: ...on the starter engine and dismount the starter engine Remove the valve cover screws and lift off the valve cover Remove the screws on the generator cover 2 and lift off the generator cover Pull out t...

Page 22: ...filter 3 with circlip pliers and discard Remove the screws and take off the thermostat connection 4 being careful not to lose the collar bushings Pull out the thermostat 5 discard the gasket Right sid...

Page 23: ...Remove the plug 6 Turn the crankshaft in a counterclockwise direction until the mark on the camshaft 7 is in alignment with the mark on the camshaft retaining bracket NOTE the mark on the camshaft ret...

Page 24: ...ve and discard the gasket Pull out the chain tensioner 2 Remove the screw 3 on the camshaft retaining brackets Remove the camshaft retaining bracket 4 Carefully pull the camshaft forward and let it ha...

Page 25: ...ly pull the cylinder up hold the piston and remove the cylinder Remove the piston bolt lock 5 with a suitable tool and slide the piston bolt 6 out of the piston holding on to the piston NOTE Push the...

Page 26: ...ew special tool 584 29 009 000 3 onto the rotor While holding the special tool turn in the screw this will pull the rotor off the crankshaft Remove the rotor and unscrew the special tool Removing the...

Page 27: ...e guide 5 out of the opening Remove the lock ring from the crankshaft with suitable pliers Use puller 590 29 033 000 6 to pull the engine sprocket off the crankshaft Removing the clutch and primary pi...

Page 28: ...NOTE the stepped disk mounted underneath usually sticks to the clutch hub Remove the stepped disk 3 Take the half disks 4 out of the groove Remove the outer clutch hub needle bearing 5 and the washer...

Page 29: ...ove the woodruff key 4 Remove both needle bearings 5 Disassembling the shift mechanism Push the shift rail 6 away from the shift lock 7 and pull out the shift shaft 8 together with the washer mounted...

Page 30: ...ve the spacing washers mounted underneath Remove both oil pump covers 4 Pull out both oil pump shafts 5 with the inner rotors take the outer rotors out of the engine case Take the lock ring 6 and wash...

Page 31: ...hafts with a plastic hammer if necessary CAUTION DO NOT PRY THE CASE HALVES APART WITH A SCREWDRIVER OR SIMILAR TOOL SINCE THIS WILL DAMAGE THE SEALING AREAS Pull the bushing and O ring for the counte...

Page 32: ...the middle shift fork will be removed from the engine case together with the transmission shafts Stand the engine case up again grasp both transmission shafts and the middle shift fork with one hand a...

Page 33: ...TING CLEARANCE OF THE PISTON 5 5 PISTON 5 6 CHECKING THE PISTON RING END GAP 5 6 CHECKING THE OIL PUMPS FOR WEAR 5 6 LUBRICATION SYSTEM 5 7 AUTOMATIC DECOMPRESSOR 5 8 TIMING CHAIN TENSIONER 5 9 TIMING...

Page 34: ...a of the engine case half rests on the surface to avoid damage a wooden panel makes a good base If possible bearings or shaft seal rings should not be hammered or tapped in at all If you do not have a...

Page 35: ...a suitable press drift tool if necessary NOTE Press the shift shaft bearing 7 in from the outside to the inside until it sits flush To avoid damage make sure the case lies flat when pressing in the b...

Page 36: ...HRAGM SUPPORT PLATE OTHERWISE ITS FUNCTION WILL BE IMPAIRED 1 2 3 4 4 5 6 7 Left case half Pry the shaft seal rings out of the crankshaft 1 and the shift shaft 2 without damaging the case Remove the s...

Page 37: ...f the crankshaft after the inner rings are replaced CAUTION NEVER LOCK THE CRANKSHAFT IN A VISE TOGETHER WITH THE CRANKPIN TO TRY TO EXTRACT THE INNER BEARING RING THIS WILL ONLY COMPRESS THE CRANKSHA...

Page 38: ...name is derived from the two materials used in the process a nickel layer in which the exceptionally hard silicon carbide is embedded The main advantages of the Nikasil coating are its outstanding he...

Page 39: ...re badly discolored or have visible running marks Place the piston pin in the conrod and check for clearance Checking the piston ring end gap Insert the piston ring in the cylinder and align with the...

Page 40: ...ou change the oil filter Inspect the oil pump rotors 6 see Checking the oil pumps for wear Thoroughly clean the oil pump rotors before remounting Check the oil pump covers 7 for seizing marks on the i...

Page 41: ...or damage or wear To remount attach the spring first and then insert the screw through the automatic decompressor weight NOTE make sure the shank of the spring 5 reaches all the way through the automa...

Page 42: ...tely again it may not be mounted in this state since the locking mechanism will not function Press down on the timing chain tensioner to ensure smooth operation To prepare the timing chain tensioner f...

Page 43: ...g chain guide 3 for seizing marks and damage Check the timing chain clip 4 for seizing marks and damage Check the timing chain 5 for damage and wear make sure the chain links operate smoothly NOTE The...

Page 44: ...rocker arm shafts 2 Insert an M6 screw in the rocker arm shafts and pull them out of the cylinder head remove the rocker arms 3 Remove the shims 4 from the valve spring retainers 5 and lay them aside...

Page 45: ...de the limit plug gauge into the valve guide have it replaced and reamed at a special machining shop Check the sealing area of the spark plug thread the valve seats for damage or cracks Use a straight...

Page 46: ...d of the valve spring with the larger diameter must be mounted facing down Preload the valve springs with the special tool and mount the valve keys NOTE make sure the valve keys are in the right posit...

Page 47: ...5 14 Repair manual KTM 690 LC4 Art No 3 206 045 E 1 2 3 4 5 4 A D 6 7 8 9 C E B 1...

Page 48: ...ls Check the shift rail 6 at the contact areas C for wear Check the return surface D on the shift rail for wear replace in case of severe indentation Check the guide bolt E for a tight fit and wear Pr...

Page 49: ...ength of the clutch springs 4 Minimum length 31 5 mm 33 5 mm new replace all 4 springs if necessary Check the pressure cap sealing area 5 for damage Check the contact face 6 of the outer clutch hub fo...

Page 50: ...he outer hub Remove the spring ring 6 and supporting ring 7 Thoroughly clean all parts Check both hubs for seizing marks and damage Check the contact area A on the lining disks for wear If the indents...

Page 51: ...ring ring and supporting ring Mount this lining disk first Position the clutch springs 3 Slide on the inner hub 4 matching the marks NOTE the outer hub has a notch 5 at the clutch spring the arrow 6 o...

Page 52: ...irclips when repairing the transmission Assembling the main shaft Clamp the main shaft in a vise with the toothed end facing down use protective jaws Carefully lubricate all parts prior to mounting Mo...

Page 53: ...with the toothed end facing down use protective jaws Carefully lubricate all parts prior to mounting Mount the split needle bearing 1 and 2nd gear idler gear 2 on the countershaft with the protruding...

Page 54: ...d bearing position of the idler gear for wear Also check the idler gear bearing bolt for running marks Mount the idler gear with the needle cage on the bearing bolt and check the clearance Freewheel g...

Page 55: ...imary pinion Check the contact area A for pressure marks thoroughly clean the primary pinion Thoroughly clean the freewheel 6 with petroleum and compressed air Check the freewheel segments for wear Ne...

Page 56: ......

Page 57: ...ANISM 6 6 MOUNTING THE STARTER DRIVE 6 6 MOUNTING THE CLUTCH AND PRIMARY PINION 6 7 MOUNTING THE TIMING CHAIN PINION AND THE TIMING CHAIN 6 9 MOUNTING THE ROTORS 6 10 MOUNTING THE PISTON CYLINDER AND...

Page 58: ......

Page 59: ...nto a vertical position Thoroughly oil all bearings Grasp both transmission shafts with one hand and insert in the bearing seats Move the engine case into a horizontal position Mount the shift forks N...

Page 60: ...sure the A and B marks are aligned Remove 585 29 005 000 from the balancer shaft Mount the stop disks for the balancer shaft 5 and main shaft 6 slide the inner bearing ring for the countershaft 7 and...

Page 61: ...6x30 M6x25 M6x30 M6x30 M6x30 M6x70 M6x30 M6x30 M6x30 M6x30 M6x70 Grease a new O ring 1 for the countershaft and insert in the collar 2 of the bushing mount the bushing with the collar facing down Moun...

Page 62: ...identical for both oil pumps The wider oil pump 1 is the suction pump the narrower pump 2 is the pressure pump Fill the oil ducts with oil and the oil pumps with grease before you mount the oil pump c...

Page 63: ...Nm Mount the pre assembled shift shaft 7 in the housing remember to include the stop disk push back the shift rail 8 and allow to engage in the shift lock Mount the shift lever and shift through all g...

Page 64: ...on the upper starter idler gear 3 with the lower collar facing the housing mount the washers and lock rings 4 on both starter idler gears Mounting the clutch and primary pinion Insert the pressure pie...

Page 65: ...n the outer clutch hub turning the transmission shafts to help it engage NOTE make sure the upper clutch disk is offset by one meshing Hold the primary pinion with special tool 750 29 081 000 3 while...

Page 66: ...the timing chain and position it on the timing chain pinion NOTE pay attention to the direction of travel if mounting a used timing chain Position and hold the clip 7 NOTE place the cable for the puls...

Page 67: ...ut using force The piston will protrude a few millimeters on the other side CAUTION THE PISTON RINGS SHOULD NOT PROTRUDE FROM THE SPECIAL TOOL Mount the piston and special tool on the liberally oiled...

Page 68: ...previously removed NOTE make sure the locating tabs 3 on the timing chain guide engage in the recess in the chain tunnel Mount the cylinder head and the oiled new cylinder head screws NOTE always rep...

Page 69: ...rrectly mounted the middle hole will be aligned directly over the hole 2 for the camshaft retaining bracket screw Mount the camshaft retaining bracket 3 in the camshaft groove apply Loctite 243 to the...

Page 70: ...JUMP WHEN THE ENGINE IS STARTED AND RESULT IN ENGINE DAMAGE Unscrew the engine locking screw 773 29 010 000 turn the crankshaft 2 turns in a counterclockwise direction and screw the engine locking sc...

Page 71: ...Lay the engine on its side fill the oil filter housing half full with engine oil and mount a new oil filter 4 Mount the oil filter cover 5 with a new O ring mount the screws M5x16 and tighten to 6 Nm...

Page 72: ...case wall and slide the oil screen all the way into the engine case Pull out the pin wrench screw in the plug A F 13 mm and tighten to 15 Nm CAUTION AN INCORRECTLY MOUNTED OIL SCREEN LOSES ITS FILTER...

Page 73: ...cover and tighten the screws to 10 Nm NOTE the gasket can usually be used again Mount a new O ring on the starter engine and grease Slide the starter engine into the bore in the engine case apply Loct...

Page 74: ......

Page 75: ...TROUBLE SHOOTING Repair manual KTM 690 LC4 Art No 3 206 045 E TROUBLE SHOOTING 9 2 INDEX 9 1 9...

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Page 77: ...safe starting system Engine cranks but doesn t start Operating error Blown fuse for the fuel pump Fuel line connection not attached The plug and socket connector on the wiring harness is oxidized Erro...

Page 78: ...eed the cooling system FI lamp is blinking lights up Error in the injection system Error diagnosis with the KTM diagnostics tool eliminate error Engine stalls while driving No fuel The fuse for the ig...

Page 79: ...CIFICATIONS Repair manual KTM 690 LC4 Art No 3 206 045 E 690 LC4 SUPERMOTO SUPERMOTO PRESTIGE ENGINE 11 2 CHASSIS 11 3 TIGHTENING TORQUES ENGINE 11 5 CHASSIS 11 6 TOLERANCES MOUNTING CLEARANCES 11 7 I...

Page 80: ......

Page 81: ...ton Light alloy forged Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Semi dry sump with 2 Eaton pumps Engine oil Motorex Cross Power 4T SAE10W 60 Quanti...

Page 82: ...es BRIDGESTONE Battlax BT090R PRO METZELER Sportec M3 160 60 R17 M C 69H 160 60 ZR17 M C 69W Air pressure Road driver only 2 0 bar Road with passenger maximum payload 2 2 bar Fuel tank capacity 13 lit...

Page 83: ...WP 4860 ROMA SUPERMOTO SUPERMOTO PRESTIGE Driving Comfort Basic Setting Driving Sport Maximum Payload Driving Comfort Basic Setting Driving Sport Maximum Payload Compression adjuster clicks 20 15 10 1...

Page 84: ...10 Nm HH screws for cylinder head M10 oiled 4 stages 15 30 45 60 Nm HH screws for cylinder head cylinder timing chain chamber M6 Loctite 243 10 Nm AH screws for cylinder head housing timing chain cham...

Page 85: ...ew for header exhaust clamp M8 copper paste 25 Nm Screw for side stand spring bracket M8 Loctite 243 25 Nm Screw for rear footrest support M8 25 Nm Screw for rear footrest bracket M8 Loctite 243 25 Nm...

Page 86: ...ing L ring 1 26 mm 1 28 mm max 1 35 mm Width of piston ring groove oil scraper ring 3 01 mm 3 03 mm max 3 1 mm Crankshaft conrod Lateral runout max 0 08 mm Outer crankshaft web dimensions 71 95 mm 72...

Page 87: ...PERIODIC MAINTENANCE SCHEDULE Repair manual KTM 690 LC4 Art No 3 206 045 E 690 LC4 12 2 INDEX 12 1 12...

Page 88: ...lter box z z Check cables for damage and kink less arrangement z z z Check headlamp adjustment z z z Check electrical system for function low high beams stop light turn indicators headlamp flasher tel...

Page 89: ...PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning every 1000 km 621 miles Check oil level z Check brake fluid level z Check brake pads for wear z Check lighti...

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Page 91: ...S Repair manual KTM 690 LC4 Art No 3 206 045 E 13 1 13 690 LC4 SUPERMOTO EXPLANATION OF CONNECTORS CABLE COLORS 13 2 START CHARGING ALARM SYSTEM 13 3 EFI 13 4 LIGHTS INSTRUMENTS FLASHER HORN COOLING F...

Page 92: ...and numbers e g C_AA1 20 The 1st position C stands for connector connector The 2nd and 3rd positions AA stand for the connector type The 4th position numbers the same type of connector if the connecto...

Page 93: ...p y m m u d m e t s y s m r a l a Antenna 8 1 J D _ C 8 1 K D _ C 1 A 1 3 2 4 5 6 8 7 9 0 1 1 1 2 1 8 1 7 1 6 1 5 1 4 1 3 1 X32 X33 X34 X35 X36 X37 X31 X38 X39 X40 X41 X42 t a e s e c n a l l i e v r...

Page 94: ...a t s e d i s r o s n e s 1 1 B 1 2 3 c i t s o n g a i d r o t c e n n o c 6 P A _ C 6 H B _ C 0 5 X 1 4 6 A 0 1 1 2 2 F A 0 1 1 2 3 F A 0 1 1 2 4 F e c i l p s 5 X 2 D 1 3 A 2 A 7 D 1 2 X D N G 6 E...

Page 95: ...ont C_CW 2 C_CX 2 H7 1 2 G d e e p s r o s n e s 3 M A _ C 3 R A _ C 8 B 1 3 2 6 B 2 1 1 X D N G 2 D 1 0 0 2 X L a l f 2 D 1 0 0 2 X R a l f 1 E3 pow X9 5 E 1 4 X g i l 5 B 2 1 P 8 B 2 B 2 1 P m e t 7...

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