KTM 690 LC4 2007 Operating instructions

690 LC4
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.045-E
REPAIRMANUAL2007

REPAIRMANUAL2007 690 LC4
KTM Group Partner

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
14
15
16

EXPLANATION - UPDATING
Edition: 01/2007
3.206.045-E Repair Manual 690 LC4
Basicversion Modelyear 2007 1/2007

INTRODUCTION
This repair manual offers extensiv repair-instructions and is an up-to-date version that describes
the latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working modes common in work shops has not been included. Safety
rules common in the work shop have also not been listed. We take it for granted that the repairs
are made by qualified profesionally trained mechanics.
Read through the repair manual before beginning with the repair work.

WARNING

STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES
UNFIT FOR TRAFFIC !
„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.
KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications,
colors, materials, services offered and rendered, and the like so as to adapt them to local
conditions without previous announcement and without giving reasons, or to cancel any of the
above items without substituting them with others. It shall be acceptable to stop manufacturing a
certain model without previous announcement. In the event of such modifications, please ask your
local KTM dealer for information.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman Company/work shop
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 – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, 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:
– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.045-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
– Enter the corresponding page number in the repair manual (e.g.: 5-7) in column 2.
– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write
your text in German or English if possible.
– Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.

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

2-2
Repair manual KTM 690 LC4 Art.-No. 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
4 750.29.055.000 Floor jack attachment
12
3
3
4

2-3
SPECIAL TOOLS – ENGINE
FIG PART NO DESCRIPTION
1 151.12.017.000 Gear puller
2 151.12.018.100 Internal gear puller 18-23 mm
3 503.29.050.000 Bleeding syringe for hydraulic clutch
4 560.12.001.000 Universal-engine work stand
5 584.29.009.000 Magneto extractor
6 584.29.037.043 Mounting tool for inner rings of crankshaft bearings
7 584.29.059.000 Loctite 648 24 ml
8 584.29.059.200 Loctite 5910 50 ml
9 585.29.005.000 Protection sleeve for shaft seal ring of water pump
10 590.29.019.000 Valve spring mounter
11 590.29.026.006 Limit plug gauge
12 590.29.033.000 Gear puller
13 590.29.041.000 Feeler gauge for valve clearance
14 6 899 785 Loctite 243 10 ml
15 750.12.001.060 Engine holder for engine work stand
16 750.12.001.070 Engine holder for engine work stand
17 750.29.015.102 Piston ring 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 press tool - optional
22 750.29.047.050 Crankshaft press-out disk upper part - optional
23 750.29.047.051 Crankshaft press-out disk lower part - optional
24 750.29.048.000 Housing separating tool
25 750.29.050.000 Mounting plate for cylinder head
26 750.29.051.000 Press-out drift for camshaft bearings
27 750.29.080.000 Protection sleeve for crankshaft seal ring flywheel side
28 750.29.080.050 Protection sleeve for crankshaft seal ring clutch side
29 750.29.081.000 Gear segment
30 750.29.090.000 Protction cap for crankshaft
31 750.29.091.000 Holding wrench for flywheel
32 750.29.094.000 Oil pressure adapter
33 750.29.172.000 Spark plug wrench
34 773.29.010.000 Crankshaft locking bolt
35 773.29.051.000 Unlatcher for timing chain tensioner
36 773.29.060.000 Insert for valve spring mounter

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
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21 22
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24 25
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27 28 29 30
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32 33 34 35 36
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34

DISASSEMBLING THE ENGINE
Repair manual KTM 690 LC4 Art.-No. 3.206.045-E
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
LEFT SIDE OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
RIGHT SIDE OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
MOVING THE ENGINE 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
DISASSEMBLING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
SEPARATING THE CASE HALVES, REMOVING THE CRANKSHAFT AND
TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
INDEX
4-1
4