2007 Ktm 690

2007 Ktm 690

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• 19

  4-1 4 Disassembling the Engine

• 33

  5-1 5 Servicing Individual Components

  • 38

    Measuring the Axial Clearance of the Crankshaft

  • 38

    Measuring the Piston and Cylinder, Establishing the Mounting Clearance of the Piston

  • 52

    General Information On Servicing the Transmission

• 57

  6-1 6 Assembling the Engine

REPAIRMANUAL2007

690 LC4

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE RÉPARATION

MANUAL DE REPARACIÓN

Chapters

• 19

  4-1 4 Disassembling the Engine

• 33

  5-1 5 Servicing Individual Components

  • 38

    Measuring the Axial Clearance of the Crankshaft

  • 38

    Measuring the Piston and Cylinder, Establishing the Mounting Clearance of the Piston

  • 52

    General Information On Servicing the Transmission

• 57

  6-1 6 Assembling the Engine

  Related Manuals for KTM 690 LC4 2007

  Summary of Contents for KTM 690 LC4 2007

• Page 1 REPAIRMANUAL2007 690 LC4 REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
• Page 3 KTM Group Partner...

• Page 5: General Information

  1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING 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 PERIODIC MAINTENANCE SCHEDULE 13 WIRING DIAGRAMS...
• Page 7 X P L A N A T I O N P D A T I N G 3.206.045-E Repair Manual 690 LC4 Basicversion Modelyear 2007 1/2007 Edition: 01/2007...
• Page 9 „NOTE" POINTS 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 professionally. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.
• Page 11 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual –...
• Page 13 GENERAL INFORMATION INDEX SPECIAL TOOLS – CHASSIS ........2-1 SPECIAL TOOLS –...
• Page 15 SPECIALTOOLS – CHASSIS PART NO DESCRIPTION 625.29.055.000 Assembly stand 750.29.034.000 Adjusting nut for swingarm bearing 750.29.036.000 Assembly stand attachment 750.29.055.000 Floor jack attachment...
• Page 16 SPECIAL TOOLS – ENGINE PART NO DESCRIPTION 151.12.017.000 Gear puller 151.12.018.100 Internal gear puller 18-23 mm 503.29.050.000 Bleeding syringe for hydraulic clutch 560.12.001.000 Universal-engine work stand 584.29.009.000 Magneto extractor Mounting tool for inner rings of crankshaft bearings 584.29.037.043 584.29.059.000 Loctite 648 24 ml 584.29.059.200 Loctite 5910 50 ml 585.29.005.000...

• Page 19: Table Of Contents

  DISASSEMBLING THE ENGINE INDEX PREPARATORY WORK ......... . .4-2 LEFT SIDE OF THE ENGINE .

• Page 21: Preparatory Work

  Preparatory work – Thoroughly clean the outside of the engine. – Drain the engine oil. – Clamp the engine in the engine work stand 560.12.001.000 with holders 750.12.001.060 and 750.12.001.070. Left side of the engine – Remove both screws on the starter engine and dismount the starter engine.

• Page 22: Right Side Of The Engine

  – Loosen the plug (A/F 13 mm) and pull out together with the oil screen – Pull the oil screen out of the plug, remove and discard all of the O- rings. – Remove the screws and oil filter cover , discard the O-ring.

• Page 23: Moving The Engine To Tdc

  – Remove the gasket and discard. – Loosen the screw on the water pump wheel and remove. – Remove the water pump wheel. – Take the washer off the water pump shaft. – Remove the screws and take off the clutch cover , discard the gasket and pull out the centering sleeves.

• Page 24: Removing The Cylinder Head And Piston

  Removing the cylinder head and piston – Unscrew the plug (A/F 19 mm) on the chain tensioner, remove and discard the gasket. – Pull out the chain tensioner – Remove the screw on the camshaft retaining brackets. – Remove the camshaft retaining bracket –...
• Page 25 – Remove the two screws – Loosen the cylinder head screws (A/F 14 mm or AH 8 mm) in a crosswise direction and remove. NOTE: always replace the cylinder head screws. – Lift off the cylinder head. – Remove the cylinder head gasket and discard.

• Page 26: Removing The Rotor

  Removing the rotor – Hold the rotor with special tool 750.29.091.000 as shown in the photo. – Unscrew the nut (A/F 27) on the rotor. NOTE: make sure the crankshaft is not locked with the locking screw. – Remove the nut and lock washer. –...

• Page 27: Removing The Clutch And Primary Pinion

  – Hold the clip while you pull out the sleeve from the tensioning rail – Lift off the tensioning rail. – Remove the timing chain from the timing chain pinion and thread it through to remove. NOTE: if you plan to mount the timing chain again, mark the direction of travel.
• Page 28 – Hold the primary pinion with special tool 750.29.081.000 while you unscrew and remove the nut (A/F 27 mm). NOTE: LH thread! – Pull the anti-hopping clutch disks out of the outer clutch hub with special tool 750.29.033.000 NOTE: the stepped disk mounted underneath usually sticks to the clutch hub.

• Page 29: Removing The Starter Drive

  4-10 – Turn the freewheel gear in a counterclockwise direction and remove the primary pinion. Removing the starter drive – Remove the lock rings with the washers mounted underneath. – Pull off both starter drive idler gears; remove the needle bearings. –...

• Page 30: Removing The Oil Pumps

  4-11 Removing the oil pumps – Remove the lock rings on both oil pump shafts. – Pull off the spacing washers and oil pump gears – Pull the needle rollers out of the pump shafts and remove the spacing washers mounted underneath. –...

• Page 31: Separating The Case Halves, Removing The Crankshaft And

  4-12 Separating the case halves, removing the crankshaft and transmission shafts – Remove all engine case screws (M6) including the screw (with copper washer) in the oil filter housing. – Lay the engine on its side. – Lift off the left case half with special tool 750.29.048.000, tapping lightly on the shafts with a plastic hammer if necessary.
• Page 32 4-13 – Tilt the shift forks to the side and pull out the shift drum – Remove the upper and lower shift fork; 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 and pull them out of the bearing seats;...
• Page 33 SERVICING INDIVIDUAL COMPONENTS INDEX RIGHT CASE HALF ..........5-2 LEFT CASE HALF .
• Page 34 IMPORTANT NOTE TO WORKING ON THE ENGINE CASE Read this section before you start to work on the engine case. Plan the precise order of assembly so that you can insert the bearings the first time the case halves are heated. To press or tap out the bearings, remove the dowels and place the engine case half on a large, level surface.

• Page 35: Right Case Half

  Right case half – Pry the shaft seal rings out of the crankshaft and the water pump shaft without damaging the case. – Remove the spraying nozzle and the oil jet – Remove the plate on the engine ventilation. – Thoroughly clean the case, removing any residual sealant.

• Page 36: Left Case Half

  Left case half – Pry the shaft seal rings out of the crankshaft and the shift shaft without damaging the case. – Remove the spraying nozzle – Thoroughly clean the case, removing any residual sealant. Blow compressed air through all oil bores. –...

• Page 37: Clutch Cover

  Clutch cover – Pry the shaft seal ring out of the crankshaft , press a new shaft seal ring all the way in with the open side on the inside. NOTE: support the clutch cover when pressing in the shaft seal ring. –...

• Page 38: Measuring The Axial Clearance Of The Crankshaft

  Measuring the axial clearance of the crankshaft – Insert the crankshaft and both transmission shafts in the right case half. Mount the left case half. – Mount and tighten the case screws. – Mount the dial gauge support on the engine case and measure the axial clearance of the crankshaft.

• Page 39: Piston

  Piston – Replace the piston if oil consumption is high or the piston skirt is excessively grooved. – If the piston is to be remounted: 1. Check the piston bearing surface for damage 2. Piston ring grooves: the piston rings must move freely in the groove. You can use old piston rings or sandpaper (400 grit) to clean the piston ring grooves.

• Page 40: Lubrication System

  bk bl Lubrication system – Replace the O-rings and sealing washer each time you change the oil filter. – Change the oil filter each with each oil change. – Inspect the O-rings for brittleness and replace if necessary; replace these O-rings when you repair the engine. –...

• Page 41: Automatic Decompressor

  Automatic decompressor – Remove the lock ring from the automatic decompressor shaft and discard. – Pull the automatic decompressor shaft out of the camshaft. – Disconnect the automatic decompressor spring, loosen the screw and remove it together with the automatic decompressor spring and the automatic decompressor weight –...

• Page 42: Timing Chain Tensioner

  Timing chain tensioner CAUTION F YOU DO NOT FOLLOW THESE INSTRUCTIONS THE TIMING CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP RESULTING IN ENGINE DAMAGE NOTE: – The timing chain tensioner operates with spring force and with oil pressure. A stop system is used to ensure the right timing chain tension in the engine starting phase, even if the oil pressure is insufficient.

• Page 43: Timing Train

  5-10 Timing train Thoroughly clean all parts and check for wear. – Check the toothing of the sprockets for chips and wear. – Check the timing chain tensioning rail for seizing marks and damage. – Check the timing chain guide for seizing marks and damage.

• Page 44: Cylinder Head

  5-11 Cylinder head – Remove all 4 screws from the rocker arm shafts – Insert an M6 screw in the rocker arm shafts and pull them out of the cylinder head; remove the rocker arms – Remove the shims from the valve spring retainers and lay them aside in their mounting position.
• Page 45 5-12 – Remove the valve keys with special tool 590.29.019.000 and 773.29.060.000 and relieve the valve springs. – Remove the special tool; remove the spring retainers and valve springs. – Pull the valve out of the bottom of the valve guide, pry off the valve stem gasket and remove the lower valve spring retainer.
• Page 46 5-13 – If you remove the valves, always replace the valve stem gaskets. – Measure the thickness of the valve spring retainers. Minimum thickness: 2.4 mm. – Position the valve spring retainers in the cylinder head. – Mount the valve stem gaskets on the valve guides and lubricate. –...
• Page 47 5-14...

• Page 48: Shift Mechanism

  5-15 Shift mechanism – Check the shift forks on the leaf for wear. The forks have a thickness of 4.85 to 4.95 mm when new, the wear limit is 4.6 mm. – Check the shift grooves on the shift drum for wear.

• Page 49: Clutch

  5-16 Clutch – Check the pressure piece for seizing marks and smooth operation. – Check the axial bearing 2 for damage. – Lay the pushrod on a level surface and check for runout. – Check the length of the clutch springs .

• Page 50: Checking The Clutch

  5-17 Checking the clutch – Clamp the clutch in a vise (use protective jaws), gradually loosen special tool 750.29.033.000 and remove. – Remove the clutch from the vise and place it on a clean workbench with the outer hub face down. –...
• Page 51 5-18 – Generously lubricate the clutch disks. – Slide the supporting ring and the spring ring on the outer hub. NOTE: mount the spring ring with the inner edge resting on the supporting ring. – Alternately slip on 8 lining disks and 7 steel disks, finishing with a lining disk on top.

• Page 52: General Information On Servicing The Transmission

  5-19 General information on servicing the transmission Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gears and check the following parts for wear or seizing marks: – Bearings – Pivot points on the main shaft and countershaft and pivot points on the idler gears –...

• Page 53: Assembling The Countershaft

  5-20 General information on servicing the transmission Clamp the main shaft or countershaft in a vise (use protective jaws). Remove the gears and check the following parts for wear or seizing marks: – Bearings – Pivot points on the main shaft and countershaft and pivot points on the idler gears –...

• Page 54: Starter Drive

  5-21 Starter drive Idler gear Check the toothing and bearing position of the starter idler gear for damage and wear. Also check the idler gear bearing bolt for running marks. Idler gear with torque limiter Check the toothing and 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.

• Page 55: Checking The Freewheel

  5-22 Checking the freewheel – Insert the freewheel gear in the primary pinion , evenly turning the primary pinion in a clockwise direction (see photo). – You should be able to turn the freewheel gear in a clockwise direction. – The freewheel gear should block in a counterclockwise direction. Replacing the freewheel –...
• Page 57 ASSEMBLING THE ENGINE INDEX MOUNTING THE TRANSMISSION SHAFTS, ASSEMBLING THE ENGINE CASE ..6-2 MOUNTING THE OIL PUMPS ........6-5 MOUNTING THE SHIFT MECHANISM .

• Page 59: Mounting The Transmission Shafts, Assembling The Engine Case

  Mounting the transmission shafts, assembling the engine case – Mount the stop disk and assemble both transmission shafts. NOTE: the countershaft has a stop disk on the bearing side, the main shaft does not. – Mount the engine case in the work stand and move into a vertical position.
• Page 60 – Grease and mount a new O-ring – Slide special tool 750.29.080.000 onto the generator end of the crankshaft. – Slide special tool 585.29.005.000 on the balancer shaft. – Insert crankshaft bearing seat remove 750.29.080.000. – Liberally lubricate the shaft seal ring for the water pump. –...
• Page 61 – Mount all engine case screws (see photo for lengths) in a crosswise direction and tighten to 10 Nm. M6x25 NOTE: mount the M6x25 screw in the oil filter housing with a new copper washer. M6x30 M6x70 M6x30 M6x30 M6x30 M6x30 M6x70 M6x30...

• Page 62: Mounting The Oil Pumps

  Mounting the oil pumps NOTE: – The outer rotors for both oil pumps are marked with an on the inside that is no longer visible when mounted. – The inner rotors for both oil pumps are marked with a on the outside that is still visible when mounted.

• Page 63: Mounting The Shift Mechanism

  Mounting the shift mechanism – Mount the locking lever with washer , sleeve and spring lock the screw with Loctite 243 and tighten to 10 Nm. – Press the locking lever away from the shift drum and mount the shift lock NOTE: the flat areas on the shift lock are not symmetrical.

• Page 64: Mounting The Clutch And Primary Pinion

  – Simultaneously slide the primary pinion and freewheel gear onto the crankshaft and the starter idler gear onto the bearing bolt, allowing the starter idler gear to engage in the freewheel toothing. – Turn the primary pinion until the shaft key engages. –...
• Page 65 – Place the half disks in the groove of the input shaft. – Slide on the stepped disk – Slide the clutch disks for the anti-hopping clutch in the outer clutch hub with special tool 750.29.033.000. – Mount the disk package in the outer clutch hub, turning the transmission shafts to help it engage.

• Page 66: Mounting The Timing Chain Pinion And The Timing Chain

  – Mounting the pressure cap – Mount the clutch screws with washers and springs and tighten in stages in a crosswise direction to 6 Nm. – Remove special tool 750.29.033.000 Mounting the timing chain pinion and timing chain – Mount the shaft key. –...

• Page 67: Mounting The Rotors

  6-10 Mounting the rotors – Slide the rotor onto the crankshaft, paying attention to the shaft key. – Mount the lock washer and nut; hold the rotor with special tool 750.29.091.000 while you tighten the nut (A/F 27 mm) to 100 –...

• Page 68: Moving The Engine To Tdc

  6-11 – Mount the piston bolt lock ring: attach the lock ring (see photo showing disassembled condition), insert special tool 750.29.035.000 in the piston bolt and press against the piston. Turn the special tool in a counterclockwise direction, causing the lock ring to be pressed into the groove.

• Page 69: Mounting The Camshaft

  6-12 Mounting the camshaft – Pull the timing chain out of the chain tunnel, only push the camshaft into the bearing far enough to be able to place the timing chain over the rear sprocket. NOTE: the middle hole of the 3 holes must be in the upper position. –...

• Page 70: Right Side Of The Engine

  6-13 – Use special tool 773.29.051.000 to press against the piston on the chain tensioner all the way to the stop to release the assembly lock and cause the piston to extend. This puts a physical load on the chain tensioner rail and tensions the timing chain. –...
• Page 71 6-14 – Slide the washer onto the water pump shaft. – Slip on the water pump wheel , apply Loctite 243 to the screws (M6x15) and tighten to 10 Nm. – Mount a new gasket in the water pump cover. –...

• Page 72: Left Side Of The Engine

  6-15 Left side of the engine – Lay the engine on its side, fill the oil filter housing half full with engine oil and mount a new oil filter – Mount the oil filter cover with a new O-ring, mount the screws (M5x16) and tighten to 6 Nm.
• Page 73 6-16 – Position the valve 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 Loctite to both screws (M6x20) and tighten to 10 Nm.
• Page 75 TROUBLE SHOOTING INDEX TROUBLE SHOOTING ..........9-2...
• Page 77 Remove the panel and fuel tank, clean the plug and socket the wiring harness is oxidized connector and spray with contact spray Error in the injection system Error diagnosis with the KTM diagnostics tool, eliminate error Engine will not reach full Air filter/fuel filter heavily soiled...
• Page 78 Repair system Air in the cooling system Bleed 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 Refuel The fuse for the ignition or fuel...
• Page 79 11-1 TECHNICAL SPECIFICATIONS INDEX 690 LC4 SUPERMOTO / SUPERMOTO PRESTIGE ENGINE ........... . 11-2 CHASSIS .
• Page 81 11-2 TECHNICAL SPECIFICATIONS – ENGINE ENGINE 690 LC4 2007 Design Single-cylinder, 4-stroke Otto engine with balancer shaft Displacement 654 cm Bore / Stroke 102 / 80 mm Compression ratio 11,8 : 1 Fuel unleaded fuel with at least RON 95 (USA: Premium PON 91)
• Page 82 Seat height, unloaded 880 mm Ground clearance, unloaded 245 mm Dry weight 154 kg Max. axle load front 150 kg Max. axle load rear 200 kg Max. total load 350 kg * further tire releases are available on the Internet at www.ktm.com...
• Page 83 11-4 FORK 690 SUPERMOTO 690 SUPERMOTO PRESTIGE Type 14.18.7C.07 WP Suspension 14.18.7C.08 WP Suspension Spring 5.2 - 430 5.2 - 430 Air chamber length 100 mm 100 mm Fork oil SAE 2.5 SAE 2.5 SHOCK ABSORBER 690 SUPERMOTO 690 SUPERMOTO PRESTIGE Type 15.18.9C.07 WP Suspension 15.18.7C.08 WP Suspension...
• Page 84 11-5 TIGHTENING TORQUES – ENGINE HH screws for ignition cover Loctite 243 + 10 Nm Plastic screw in ignition cover M24x1.5 8 Nm AH plug for oil bore M14x1.5 Loctite 243 + 15 Nm AH plug for oil bore M10x1 Loctite 243 + 15 Nm Torx plug for oil bore self-tapping...
• Page 85 11-6 TIGHTENING TORQUES – CHASSIS Screw for side stand switch Loctite 243 + 2 Nm Spoke nipple M4,5/M5 5 Nm Screw for fuel pump, pressure regulator 4 Nm Screw for fuel level sensor 3 Nm Screw for foot brake pedal surface Loctite 243 + 6 Nm Screw for plastic clamp brake line fork leg 2 Nm...
• Page 86 11-7 TOLERANCES AND FITTING CLEARANCE COMPONENT MEASUREMENT/TEST ..... . .SETPOINT VALUE .TOLERANCE LIMIT Valves Valve clearance (at 20ºC) intake ....0.07 mm - 0.13 mm Valve clearance (at 20ºC) exhaust .
• Page 87 12-1 PERIODIC MAINTENANCE SCHEDULE INDEX 690 LC4 ........... .12-2...
• Page 88 IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM (3107 MILES) SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceeded by more than 500 km (311 miles). Maintenance work performed by an authorized KTM workshop is not a substitute for care and maintenance by the driver!
• Page 89 12-3 690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007 ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER at least every 10000 km once a year (6214 miles) or every 2 years Perform complete fork maintenance Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease...
• Page 91 13-1 WIRING DIAGRAMS INDEX 690 LC4 SUPERMOTO EXPLANATION OF CONNECTORS, CABLE COLORS ..... . .13-2 START/CHARGING-/ALARM SYSTEM ....... .13-3 EFI .
• Page 92 13-2 NOTE to the connector designations: The connector designations are comprised of letters 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 connector is used for different applications. –The 5th and 6th positions 20 specify the number of pins in the connector, in this case 20 poles.
• Page 93 13-3...
• Page 94 13-4...
• Page 95 13-5...

2007 Ktm 690

Source: https://www.manualslib.com/manual/799623/Ktm-690-Lc4-2007.html

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