2007_LC4_690_Repair_.. - Syndicate Central

REPAIRMANUAL2007 690 LC4 REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION

ART.NR.: 3.206.045-E

MANUAL DE REPARACIÓN

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 3.206.045-E Repair Manual 690 LC4 Basicversion Modelyear 2007

1/2007

Edition: 01/2007

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 ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB. !

CAUTION

IS

!

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

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 – 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.

Item no. of repair manual

Page

Current text

Correct text

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

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2-1

GENERAL INFORMATION INDEX

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

2

2-2

SPECIALTOOLS – CHASSIS

3

Art.-No. 3.206.045-E

3

1


FIG 1 2 3 4

PART NO 625.29.055.000 750.29.034.000 750.29.036.000 750.29.055.000

4

2

DESCRIPTION Assembly stand Adjusting nut for swingarm bearing Assembly stand attachment Floor jack attachment

2-3

SPECIAL TOOLS – ENGINE FIG 1 2 3 4 5 6 7 8 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

PART NO 151.12.017.000 151.12.018.100 503.29.050.000 560.12.001.000 584.29.009.000 584.29.037.043 584.29.059.000 584.29.059.200 585.29.005.000 590.29.019.000 590.29.026.006 590.29.033.000 590.29.041.000 6 899 785 750.12.001.060 750.12.001.070 750.29.015.102 750.29.021.000 750.29.033.000 750.29.035.000 750.29.047.000 750.29.047.050 750.29.047.051 750.29.048.000 750.29.050.000 750.29.051.000 750.29.080.000 750.29.080.050 750.29.081.000 750.29.090.000 750.29.091.000 750.29.094.000 750.29.172.000 773.29.010.000 773.29.051.000 773.29.060.000

DESCRIPTION Gear puller Internal gear puller 18-23 mm Bleeding syringe for hydraulic clutch Universal-engine work stand Magneto extractor

Mounting tool for inner rings of crankshaft bearings Loctite 648 24 ml Loctite 5910 50 ml Protection sleeve for shaft seal ring of water pump Valve spring mounter Limit plug gauge Gear puller Feeler gauge for valve clearance Loctite 243 10 ml Engine holder for engine work stand Engine holder for engine work stand Piston ring mounting tool Puller for primary gear Mounting screws for Anti hopping clutch Mounting tool for piston pin retainer Crankshaft press tool - optional Crankshaft press-out disk upper part - optional Crankshaft press-out disk lower part - optional Housing separating tool Mounting plate for cylinder head Press-out drift for camshaft bearings Protection sleeve for crankshaft seal ring flywheel side Protection sleeve for crankshaft seal ring clutch side Gear segment Protction cap for crankshaft Holding wrench for flywheel Oil pressure adapter Spark plug wrench Crankshaft locking bolt Unlatcher for timing chain tensioner Insert for valve spring mounter

2-4 1

2 4

3 5 6 7

8

9

10

12

11

13

14

15 16

Art.-No. 3.206.045-E

17

18 19

20

22

21

24

25 26


23

28

27

29

30 31

32

33

34

35

36

4-1

DISASSEMBLING THE ENGINE


Art.-No. 3.206.045-E

INDEX

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

4

4-2 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 1 on the starter engine and dismount the starter engine.

1 – Remove the valve cover screws and lift off the valve cover.

Art.-No. 3.206.045-E

– Remove the screws on the generator cover 2 and lift off the generator cover. Pull out the centering sleeves, remove and discard the gasket. – Remove the gear sensor 3.

3 2 – Remove both contact bolts 4 and the O-ring 5. – Take both contact springs 6 out of the bores.

4 Repair manual KTM 690 LC4

5 4 6

4-3 – Loosen the plug (A/F 13 mm) and pull out together with the oil screen 1. – Pull the oil screen out of the plug, remove and discard all of the Orings.

1 – Remove the screws and oil filter cover 2, discard the O-ring.

3

2

– Pull out the oil 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.

5

4

Right side of the engine

7

– Unscrew the oil filling plug and remove. – Remove the screws and take off the oil filter cover 6, discard the Oring. – Pull out the oil filter 7 with circlip pliers and discard.

6 – Remove the screws and take off the water pump cover 8.

8

4-4 – Remove the gasket and discard. – Loosen the screw on the water pump wheel 1 and remove.

2

– Remove the water pump wheel. – Take the washer 2 off the water pump shaft.

1 – Remove the screws and take off the clutch cover 3, discard the gasket and pull out the centering sleeves.

3

– Unscrew the temperature sensor 4 (A/F 19 mm) and spark plug 5 (750.29.172.000). Art.-No. 3.206.045-E

5 4 Moving the engine to TDC


– Remove the plug 6.

6

9 – 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.

8

NOTE: the mark on the camshaft retaining bracket is in the middle of the screw 8. – Screw on the engine locking screw 773.29.010.000, make sure the engine is locked. ! DO

7

CAUTION

!

NOT USE THE LOCKING SCREW TO HOLD THE CRANKSHAFT WHEN YOU UNSCREW OR TIGHTEN THE NUTS ON THE FLYWHEEL OR PRIMARY PINION SINCE ENGINE PARTS WILL BE DAMAGED.

4-5 Removing the cylinder head and piston – Unscrew the plug 1 (A/F 19 mm) on the chain tensioner, remove and discard the gasket.

1 – Pull out the chain tensioner 2.

2 – Remove the screw 3 on the camshaft retaining brackets.

4

– Remove the camshaft retaining bracket 4.

3 – Carefully pull the camshaft forward and let it hang down.

– Remove the timing chain from the camshaft. Now you can remove the camshaft.

4-6 – Remove the two screws 1.

2

2

– Loosen the cylinder head screws 2 (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.

2 1

2 1 – Remove the cylinder head gasket 3 and discard.

3

– Remove the screw 4.

4 Art.-No. 3.206.045-E

– Carefully 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.


6

NOTE: – Push the piston bolt out with your finger, do not use a tool. – If you plan to use the piston again, it is advisable to remove the lock ring on the clutch end. – Lift off the cylinder base gasket and discard.

5

4-7 Removing the rotor

1

– Hold the rotor 1 with special tool 750.29.091.000 2 as shown in the photo.

2

– 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.

– Screw 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.

3

– Remove the rotor and unscrew the special tool.

Removing the timing chain and timing chain pinion – Remove the screws 4 on the timing chain guides.

4 4 – Lift the guide rail 5 out of the clip 6.

7

6

5

NOTE: the sleeve 7 is inserted through the guide rail and clip. – Lift off the guide rail.

4-8

3 2 1

– Hold the clip 1 while you pull out the sleeve 2 from the tensioning rail 3. – 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.

– Remove the screws on the pulse generator 4 and remove the pulse generator. – Pull the cable guide 5 out of the opening.

4

5 – Remove the lock ring from the crankshaft with suitable pliers.

Art.-No. 3.206.045-E

– Use puller 590.29.033.000 6 to pull the engine sprocket off the crankshaft.

6 Removing the clutch and primary pinion

7


8

– Clamp the anti-hopping clutch with special tool 750.29.033.000 7. NOTE: only tighten special tool 750.29.033.000 by hand; do not use a tool to tighten. – Loosen the clutch screws in stages in a crosswise direction and remove together with the washers and springs. – Remove the pressure cap 8.

7

– Bend up the lock washer on the nut. – Hold the outer clutch hub with special tool 750.29.081.000 9 while you unscrew the nut (A/F 30 mm).

9

4-9 – Hold the primary pinion with special tool 750.29.081.000 1 while you unscrew and remove the nut (A/F 27 mm). NOTE: LH thread!

1 – Pull the anti-hopping clutch disks out of the outer clutch hub with special tool 750.29.033.000 2. NOTE: the stepped disk mounted underneath usually sticks to the clutch hub.

2 – Remove the stepped disk 3.

3

4 4

– Take the half disks 4 out of the groove.

– Remove the outer clutch hub, needle bearing 5 and the washer 6 mounted underneath.

6

– Remove the pressure piece 7 and the pushrod.

5 7 9 8

– Mount special tool 750.29.021.000 8 on the primary pinion 9 and hold (A/F 24 mm) while you turn in the screw (A/F 19 mm); this will pull the primary pinion off the crankshaft.

4-10

1

– Turn the freewheel gear 1 in a counterclockwise direction and remove the primary pinion.

Removing the starter drive – Remove the lock rings 2 with the washers mounted underneath. – Pull off both starter drive idler gears; remove the needle bearings.

2

2 – Take the freewheel gear 3 off the crankshaft and remove the woodruff key 4. – Remove both needle bearings 5.

Art.-No. 3.206.045-E

4 5 3

Disassembling the shift mechanism

9

7

– Push the shift rail 6 away from the shift lock 7 and pull out the shift shaft 8 together with the washer mounted underneath.


– Remove the screw 9 (AH 5 mm) on the shift lock.

8

6 – Press the locking lever bk down to relieve the shift lock 7, remove the shift lock. – Loosen the screw and remove the locking lever together with the washer and spring.

7 bk

4-11 Removing the oil pumps – Remove the lock rings 1 on both oil pump shafts. – Pull off the spacing washers and oil pump gears 2.

1 2 – Pull the needle rollers 3 out of the pump shafts and remove the spacing washers mounted underneath.

3

4

4

– Remove both oil pump covers 4.

3 – Pull out both oil pump shafts 5 with the inner rotors; take the outer rotors out of the engine case.

5 5 – Take the lock ring 6 and washer off the countershaft.

6

– Loosen the plug (A/F 13 mm) and pull it out together with the oil screen 7. – Pull the oil screen out of the plug; remove all O-rings and discard.

7

4-12 Separating the case halves, removing the crankshaft and transmission shafts

S

– Remove all engine case screws (M6) including the screw S (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. !

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 countershaft out of the shaft seal ring in the countershaft and discard the O-ring. NOTE: the main shaft and the balancer shaft have a stop disk that usually sticks to the bearing; be careful not to lose them.

– Lift the balancer shaft 1 out of the bearing. Art.-No. 3.206.045-E

– Lift the crankshaft 2 out of the bearing.

1

2


– Remove the O-ring 3.

3 – Pull out the shift rail 4.

4

4-13 – Tilt the shift forks 1 to the side and pull out the shift drum 2.

1

– Remove the upper and lower shift fork; the middle shift fork will be removed from the engine case together with the transmission shafts.

2

– 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; make sure the engine case cannot fall off the work stand.

5-1

SERVICING INDIVIDUAL COMPONENTS


Art.-No. 3.206.045-E

INDEX

RIGHT CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 LEFT CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 CRANKSHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 DRIVE WHEEL ON THE BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 MEASURING THE AXIAL CLEARANCE OF THE CRANKSHAFT . . . . . . . . . . . . . . . . .5-5 CYLINDER - NIKASIL COATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 MEASURING THE PISTON AND CYLINDER, ESTABLISHING THE MOUNTING 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 TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 PRE-MOUNTING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 CHECKING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 GENERAL INFORMATION ON SERVICING THE TRANSMISSION . . . . . . . . . . . . . .5-19 ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 CHECKING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22 REPLACING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5

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. Make sure the entire sealing area 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 pressing tool, carefully tap them in with a suitable drift. Cold bearings usually fall into the bearing seats automatically at an engine case temperature of approximately 150° C. If the bearings do not fit tightly in their mounts when the case half has cooled down, they may turn in the engine case when they warm up. In this case the engine case must be replaced.

5-2 Right case half – Pry the shaft seal rings out of the crankshaft 1 and the water pump shaft 2 without damaging the case.

5

– Remove the spraying nozzle 3 and the oil jet 4.

8

– Remove the plate 5 on the engine ventilation. – Thoroughly clean the case, removing any residual sealant. Blow compressed air through all oil bores. – Remove all bearing retainers 6. – Pull the dowels out of the case.

8

2

1

– Push new bearings into the bearing seats while the engine case is still hot. Press all the way in from the inside to the outside, using a suitable press/drift tool if necessary.

3 6 Art.-No. 3.206.045-E

– Heat the case in the oven to approx. 150° C and tap on a level wooden board, causing the bearings to drop out of the bearing seats. Any bearings that remain in the case must be pressed out with a suitable press/drift tool.

6

6

6 6 7

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 bearings. – Always press in bearings on the outer ring or the bearings will be damaged in the process. – Check the bearings for a tight fit when the case has cooled. – Mount all bearing retainers, lock screws with Loctite 648 and tighten to 5 Nm.

– Press in a new crankshaft seal ring 1 with the open side towards the inside until it sits flush. – Press in a new water pump shaft seal ring 2 with the open side towards the outside until it sits flush. – Inspect the oil pump housing 8 for score marks or seizing marks.


– Apply Loctite 648 to the spraying nozzle 50 3 and tighten to 6 Nm.

4

– Apply Loctite 648 to the oil jet 125 4 and tighten to 2 Nm. – Mount the plate 5 on the engine vent, lock the screws (AH M5x12) with Loctite 243 and tighten to 3 Nm. – Mount the dowels again.

5-3 Left case half – Pry the shaft seal rings out of the crankshaft 1 and the shift shaft 2 without damaging the case. – Remove the spraying nozzle 3. – Thoroughly clean the case, removing any residual sealant. Blow compressed air through all oil bores. – Remove all bearing retainers 4. – Remove the plug 5 and take the pressure spring 6 and bypass valve 7 out of the hole. – Pull the dowels out of the case.

1

– Unscrew the diaphragm support plate 8 (TX 10) and remove together with the diaphragm. – Heat the case in the oven to approx. 150° C and tap on a level wooden board, causing the bearings to drop out of the bearing seats. Any bearings that remain in the case must be pressed out with a suitable press/drift tool.

2 3

– Push new bearings into the bearing seats while the engine case is still hot. Press all the way in from the inside to the outside, using a suitable press/drift tool if necessary.

4

NOTE: – To avoid damage, make sure the case lies flat when pressing in the bearings. – Always press in bearings on the outer ring or the bearings will be damaged in the process. – Check the bearings for a tight fit when the case has cooled.

4

6

– Mount all bearing retainers, lock screws with Loctite 648 and tighten to 5 Nm.

7

– Press in a new shaft seal ring for the crankshaft 1 and the shift shaft 2 with the open side towards the inside until it sits flush.

5

– Remove the bypass valve, inspect for score marks or seizing marks, measure the length of the pressure spring. Minimum length of the pressure spring: 25 mm – Oil the bypass valve and mount with the spring, screw in the plug with a new seal ring and tighten to 20 Nm. – Apply Loctite 648 to the thread of the spraying nozzle 50 3 and tighten to 6 Nm. – Mount the dowels again. – Mount the diaphragm support plate 8 and the diaphragm 9 again. Use some Loctite 243 on the threads of the screws (M3x8) and tighten. NOTE: the diaphragm support plate is curved and must point away from the diaphragm.

8

8 9

! – AN –

CAUTION

!

INCORRECTLY MOUNTED DIAPHRAGM SUPPORT PLATE WILL LEAD TO POOR PERFORMANCE AND EXCESSIVE OIL CONSUMPTION OR LEAKS. MAKE SURE NO LOCTITE 243 DRIPS BETWEEN THE DIAPHRAGM AND THE DIAPHRAGM SUPPORT PLATE OTHERWISE ITS FUNCTION WILL BE IMPAIRED.

5-4 Clutch cover – Pry the shaft seal ring out of the crankshaft 1, 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. – Blow compressed air through the oil duct and make sure it is not clogged.

1 Crankshaft bearing – Clamp the crankshaft in a vise, using protective jaws. – Heat special tool 584.29.037.043 on a hotplate to approx. 150° C and immediately slide it onto the inner ring. Squeeze the special tool together tightly to obtain a good heat transfer and pull the inner ring off the crankshaft. – To mount the new inner ring, reheat the special tool to approx. 150°C, clamp the inner ring and immediately slide it onto the crankshaft journal. – Make sure the new inner ring sits flush. – Measure the axial clearance of the crankshaft after the inner rings are replaced. !

CAUTION

!

Art.-No. 3.206.045-E

NEVER

2

2

LOCK THE CRANKSHAFT IN A VISE TOGETHER WITH THE CRANKPIN TO TRY TO EXTRACT THE INNER BEARING RING. THIS WILL ONLY COMPRESS THE CRANKSHAFT WEBS AND MAKE THE CRANKSHAFT UNUSABLE.

Drive wheel on the balancer shaft NOTE: remove the inner ring from the roller bearing before you remove the balancer shaft drive wheel from the crankshaft. – Insert the 2 M6 screws 2 in the threaded holes. – Tighten the two screws evenly and pull the drive wheel from the crankshaft. – To mount the drive wheel, heat it to approx. 100° C. – Mount the drive wheel on the crankshaft; the dowel on the crankshaft must slide into the hole 3. NOTE: the side of the drive wheel with the punch mark 5 must face you after mounting, the side with the chamfer 4 faces the crankshaft web.

5 Repair manual KTM 690 LC4

4 3 – After mounting, check the position of the dowel and the punch mark: the dowel should slide into the hole 3, the mark 5 should be visible. ! MAKE

CAUTION

!

SURE THE DOWEL DOES NOT PROTRUDE ON THE OTHER SIDE OF THE CRANKSHAFT WEB.

5 3

5-5 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. Axial clearance of the crankshaft: 0.15 - 0.25 mm – If the measured value does not correspond to the set-point value, correct the axial clearance. – Remove the crankshaft and pull the inner ring off the crankshaft on the ignition side using special tool 584.29.037.043. Now either add or remove compensating washers. NOTE: If the axial clearance is too large, add compensating washers; if it is too small, remove some of the washers. Compensating washers may only be added on the ignition side.

Cylinder - Nikasil coating Nikasil is a trademarked cylinder coating process developed by the Mahle piston manufacturer. The 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 heat dissipation, the improved power output, low wear and the low weight of the cylinder.

1

Measuring the piston and cylinder, establishing the mounting clearance of the piston – To establish the wear to the cylinder, use a micrometer to measure the cylinder in the middle of the bearing surface. – Measure the diameter of the cylinder in the X and the Y axis to detect any ovality.

x y

Cylinder diameter

size I: 102.000 - 102.012 mm size II: 102.013 - 102.025 mm wear limit: max. 102.04 mm

NOTE: the cylinder size 1 is marked on the side of the cylinder, the piston size 2 on the piston head.

2

– The piston is measured at the piston skirt across the piston pin, as illustrated. Piston diameter

size I: 101.955 - 101.965 mm size II: 101.966 - 101.975 mm

– The piston mounting clearance is the difference between the smallest cylinder diameter and the piston diameter. Piston mounting clearance min. 0.03 mm - max. 0.10 mm

5-6 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. 3. Check the piston rings for damage and end gap. Mount the oil scraper ring with the "TOP" mark facing up. Mount the rectangular ring with the "O" mark facing up. 4. Replace piston pins that are 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 piston (approx. 10 mm under the upper edge of the cylinder). – Use a feeler gauge A to measure the end gap.

A

Compression ring : max. 0.80 mm Oil scraper ring : max. 1.00 mm If the end gap is larger than indicated above, check the cylinder for wear. If the cylinder wear is within the tolerance limits, replace the piston ring.

Checking the oil pumps for wear Art.-No. 3.206.045-E

– Position the inner and outer rotors in the engine case with the marks facing the case (not visible).

B

– Use a feeler gauge B to measure the wear: Outer rotor - oil pump housing: max. 0.20 mm

Outer rotor - inner rotor: max. 0.20 mm


B

5-7

9

7 6 8

9

7

8

6

1 2 bk bl 2 1

1

4

3

3

4

3 5

1

3

1

Lubrication system – Replace the O-rings and sealing washer 1 each time you change the oil filter. – Change the oil filter 2 each with each oil change. – Inspect the O-rings 3 for brittleness and replace if necessary; replace these O-rings when you repair the engine. – Clean the oil screen 4 with compressed air and petroleum; replace if damaged. – Thoroughly clean the magnet on the oil plug 5 each time you 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 inside and replace if necessary. – Lay the oil pump shaft 8 on a level surface and check for runout. – Check the teeth on the oil pump gears 9 for wear. The recesses for the needle rollers should not be worn-out. – Check the pressure control piston bk for wear and score marks. – Check the length of the spring bl for the pressure control piston (see page 5-3).

5-8 Automatic decompressor – Remove the lock ring 1 from the automatic decompressor shaft and discard.

1

– Pull the automatic decompressor shaft 2 out of the camshaft.

2 – Disconnect the automatic decompressor spring, loosen the screw 3 and remove it together with the automatic decompressor spring and the automatic decompressor weight 4.

Art.-No. 3.206.045-E

3 4

– Check all parts for 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 automatic decompressor weight. – Mount the automatic decompressor weight, lock the screw with Loctite 243 and tighten to 3-4 Nm. Attach the spring again.


5

– Mount the automatic decompressor shaft in the camshaft and insert the new lock ring in the groove. – Perform a functional check; the spring should turn the automatic decompressor shaft all the way back. If not, increase the preload or replace.

5-9 Timing chain tensioner !

1

CAUTION

!

YOU DO NOT FOLLOW THESE INSTRUCTIONS, THE TIMING CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP, RESULTING IN ENGINE DAMAGE.

IF

2

NOTE: – The timing chain tensioner 1 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. The stop system prevents the piston 2 on the timing chain tensioner from being retracted. – In a dismounted state, the piston on the timing chain tensioner extends completely. – Fully depress the spring tensioner. This will require some effort since the oil must be squeezed out. If the timing chain tensioner is released it will extend completely 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 for installation, place 2 spacing washers or similar implements with a thickness of 2 - 2.5 mm next to the piston of the timing chain tensioner. This will ensure that the piston cannot be completely retracted when the piston is pressed down. If you release the piston, the stop system will lock, the piston will protrude approx. 3 mm and stay in this position - this position is required for refitting!

– If you press the timing chain tensioner again and it extends no more than half way (preventing it from extending completely), the stop system will lock and the timing chain tensioner can no longer be pressed together - this position is necessary to ensure that the timing chain is adequately tensioned, even if the oil pressure is low.

5-10 Timing train Thoroughly clean all parts and check for wear. – Check the toothing of the sprockets 1 for chips and wear.

1

– Check the timing chain tensioning rail 2 for seizing marks and damage.

2

5

3

– Check the timing 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 smooth operation of the chain links can easily be checked by simply letting the timing chain hang down - the chain links should align in a row. Replace the timing chain if the chain links do not align in a row - they are no longer free-moving.

4


Art.-No. 3.206.045-E

1

5-11

2 3 4 5

3

1 1

1

4 5

Cylinder head – Remove all 4 screws 1 from the rocker arm shafts 2.

1 – Insert an M6 screw in the rocker arm shafts and pull them out of the cylinder head; remove the rocker arms 3.

2

– Remove the shims 4 from the valve spring retainers 5 and lay them aside in their mounting position.

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.

Art.-No. 3.206.045-E

NOTE: if you are mounting the used valves again, they must be remounted in the same valve guide as before. For this purpose, place the valves in a box, marking the position they were mounted in the cylinder head (see photo).


– Check the valve guides with the limit plug gauge 590.29.026.006 1 (Ø 6.05 mm). If you can easily slide the limit plug gauge into the valve guide, have it replaced and reamed at a special machining shop.

1

– Check the sealing area of the spark plug thread the valve seats for damage or cracks. Use a straight edge and a feeler gauge to check the warpage of the sealing area towards the cylinder. Warpage: max. 0.10 mm. – Valve seats should not be impacted. Sealing seat width: inlet max. 1.60 mm; outlet max. 2.00 mm. If necessary, grind the valves. – Check the valve disk for wear and runout. Max. runout at the valve disk: 0.05 mm. The valve seat may not be impacted. The sealing area should be in the center of the valve seat. The valve stem is hard-chromium-plated, the valve guide is usually subjected to wear. – Check whether the valve springs are broken or worn (visual check). Also measure the length with a sliding caliper. Minimum length 42.3 mm NOTE: replace the spring if it is shorter.

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. – Generously lubricate the valves on the stem and insert in the valve guides. NOTE: make sure you mount the valves in the right position. – Position the valve springs, place the valve spring retainers in the valve springs. NOTE: the end of the valve spring with the larger diameter must be mounted facing down.

1

– Preload the valve springs with the special tool and mount the valve keys. NOTE: make sure the valve keys are in the right position when mounted. Attach the valve keys to the valve with a little grease. – Finally, tap the valve spring retainers a few times with a plastic hammer. – Mount the shims in their original position. – Position the rocker arms and slide in the rocker arm shafts. NOTE: the threaded holes must be on the chain tunnel side.

3

3

!

CAUTION

!

YOU MOUNT THE ROCKER ARM SHAFTS, MAKE SURE THE SMALL HOLES FACE UP.

WHEN

1

– Mount the M6x40 screws 2 on the rocker arm shafts, mount the M6x30 screws 3 and tighten to 12 Nm.

2


Art.-No. 3.206.045-E

5-14

D 6

E 8

C 9

7

A 1

4 5 1

2

B

4

3

5-15 Shift mechanism – Check the shift forks 1 on the leaf A 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 B on the shift drum 2 for wear. – Check the fit of the shift drum in the grooved ball bearing 3. – Check the grooved ball bearing 3 for smooth operation. – Check the shaft rollers 4 for pressure points and cracks. – Check the shift rails 5 for runout on an even surface. Check the shift rails for score marks and seizing marks. The shift forks must operate smoothly on the shift rails. – 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.

F

– Pre-mount the shift shaft and check the clearance F between the shift rail 6 and the shift quadrant. The clearance must lie between 0.40 - 0.80 mm.

Pre-mounting the shift shaft

bk

– Clamp the short end of the shift shaft in a vise (use protective jaws). – Mount the shift rail 6 with the guide bolt facing down and attach the guide bolt to the shift quadrant. – Mount the pressure spring 7.

6

7

9 8

– Slide on the spring guide 8, slide the return spring 9 over the spring guide with the angled end up and lift the angled end over the dolly bolt bk (see illustration). – Mount the stop disk bl.

bl

5-16

4

9 5

2 1

6

8

3

Art.-No. 3.206.045-E

7

Clutch – Check the pressure piece 1 for seizing marks and smooth operation. – Check the axial bearing 2 for damage. – Lay the pushrod 3 on a level surface and check for runout. – Check the length 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 for wear. If the indents are bigger than 0.5 mm, replace the lining disks and the outer clutch hub. – Check the needle bearing 7 for seizing marks and damage.


– Inspect the lining disks 8 and clutch disks 9 (see next page).

5-17 Checking the clutch

2

– Clamp the clutch in a vise (use protective jaws), gradually loosen special tool 750.29.033.000 1 and remove.

1 – Remove the clutch from the vise and place it on a clean workbench with the outer hub 2 face down.

4

– Remove the inner hub 3 and clutch springs 4 from the outer hub.

3 – Remove the clutch disks 5 from the outer hub.

7

5 A

– Remove the spring ring 6 and supporting ring 7. – Thoroughly clean all parts.

– Check both hubs for seizing marks and damage.

6

– Check the contact area A on the lining disks for wear. If the indents are larger than 0.5 mm, replace the lining disks and the outer clutch hub. – Check the thickness of the lining disks; minimum thickness: 2.5 mm. The lining disks must be flat. – Clutch disks must be flat. Check for mechanical damage. Replace the clutch disks if you detect any roughness or chipped material.

5-18 – Generously lubricate the clutch disks. – Slide the supporting ring 1 and the spring ring 2 on the outer hub.

A 2

1

NOTE: mount the spring ring with the inner edge A resting on the supporting ring.

– Alternately slip on 8 lining disks and 7 steel disks, finishing with a lining disk on top.

3

NOTE: the outer lining disk has a larger inner diameter since it must be positioned over the spring ring and supporting ring. Mount this lining disk first. – Position the clutch springs 3.

4 Art.-No. 3.206.045-E

– Slide on the inner hub 4, matching the marks.

6

NOTE: the outer hub has a notch 5 at the clutch spring, the arrow 6 on the inner hub must point to the notch. – Tightly press the two hubs together and have a helper screw on special tool 750.29.033.000. !

5

DO

CAUTION

!

NOT TIGHTEN WITH A TOOL.

NOTE: tighten special tool 750.29.033.000 just enough to allow the clutch disks to be turned since they must be aligned when mounted in the outer clutch hub.


– Align the lining disks with the outer clutch hub, turning the upper disk one space.

5-19

1

2 3 4

5

6 7 9 8 bk bl

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 – Gear dogs – Tooth faces on all gears – Tooth profiles on the main shaft and countershaft and the corresponding gears – Check all sliding gears for smooth operation in the profile Carefully clean all parts and replace any damaged parts. Always mount new circlips 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. – Mount the split needle bearing 1, mount the 5-speed idler gear 2 with the shift dogs facing up. – Mount the stop disk 3 (20x32x1mm) and the circlip 4. – Mount the 3rd/4th gear sliding gear 5 with the small gear facing down; mount the shaft ring 6. – Mount the stop disk 7 and split needle bearing 8. – Mount the 6th gear idler gear 9 with shift dogs facing down. – Mount the 2nd gear fixed gear bk with the collar facing down; mount the stop disk bl (20x32x1mm). – Finally, check all gears for smooth operation. NOTE: 3 and bl are identical.

5-20

br

bs

bq

bp

bo bn

bm bl

7 6

bk 9

5

8

4 3

2

Art.-No. 3.206.045-E

1

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 – Gear dogs – Tooth faces on all gears – Tooth profiles on the main shaft and countershaft and the corresponding gears – Check all sliding gears for smooth operation in the profile


Carefully clean all parts and replace any damaged parts. Always mount new circlips when repairing the transmission.

Assembling the countershaft – Clamp the countershaft in a vise 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 collar facing down. – Mount the thrust washer 3 and the lock ring 4. – Mount the 6th gear sliding gear 5 with the shift groove facing up. – Mount the lock ring 6 and the stop disk 7. – Mount the 2 split needle bearings 9 + bl and the 4th gear idler gear 8 with the collar facing up. – Mount the 3rd gear idler gear bk with the collar facing down. – Mount the stop disk bm and lock ring bn. – Mount the 5-speed sliding gear bo with the shift groove facing down; mount the stop disk bp (22x31.7x1mm). – Mount the needle bearing bq, 1st gear idler gear br with the recess facing down; mount the stop disk bs (20x32x1mm). NOTE: – 3, 7 and bm are identical. – 9 and bl are identical.

5-21

6 5

1 2

3 4

Starter drive Idler gear 1 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 2 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. Freewheel gear 3 Check the toothing and bearing position for wear. Freewheel 4 Disassemble the freewheel (see next page) and check for damage and wear. Starter engine 5 Check the toothing for wear; replace the O-ring 6 on the flange.

5-22 Checking the freewheel – Insert the freewheel gear 1 in the primary pinion 2, 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.

2

1

Replacing the freewheel

3

4

Art.-No. 3.206.045-E

5

A

6

– Remove the lock ring 3 from the groove with suitable pliers.

– Squeeze the spreader ring 4 together with suitable pliers and remove. – Lift the freewheel 5 out of the primary 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. Next, generously lubricate the freewheel.


NOTE: if you detect any damage that requires the parts to be replaced, replace both as a set. – Insert the freewheel in the primary pinion.

– Mount the spreader ring; make sure all of the tabs on the spreader ring slide into the freewheel grooves. If necessary, use a screwdriver to press them in. – Insert the lock ring 3 in the groove with suitable pliers and make sure it is fully seated. It is recommended to carefully tap on the mounted spreader ring with a drift punch.

B

B

6-1

ASSEMBLING THE ENGINE


Art.-No. 3.206.045-E

INDEX

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

6

6-2

1

Mounting the transmission shafts, assembling the engine case – Mount the stop disk 1 and assemble both transmission shafts.

2 3

NOTE: the countershaft has a stop disk on the bearing side, the main shaft does not.

4 – Mount the engine case in the work stand and move into 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.

Art.-No. 3.206.045-E

NOTE: – Upper shift fork 2, middle shift fork 3, lower shift fork 4 (see photo at the top). – Lift the sliding gear for 3/4 gear to mount the middle shift fork.

3

2

4 – Mount the shift drum 5 and allow the needle rollers 6 to engage in the shift forks.


5 6 – Align the shift forks and mount the shift rail 7.

7

6-3 – Grease and mount a new O-ring 1.

1 – Slide special tool 750.29.080.000 2 onto the generator end of the crankshaft. – Slide special tool 585.29.005.000 3 on the balancer shaft.

3

2

– Insert the crankshaft 750.29.080.000.

in

the

bearing

seat

and

remove

– Liberally lubricate the shaft seal ring for the water pump. – Insert the balancer shaft 4 in the bearing seat, making sure the A and B marks are aligned. – Remove 585.29.005.000 from the balancer shaft.

4

A

B – Mount the stop disks for the balancer shaft 5 and main shaft 6, slide the inner bearing ring for the countershaft 7 and special tool 750.29.080.050 8 onto the crankshaft.

5

6 8

– Degrease the sealing area and apply a thin layer of Loctite 5910 (584.29.059.200). – Mount the left case half, tapping lightly with a plastic hammer if necessary.

7

!

CAUTION

!

DO NOT PULL THE CASE HALVES TOGETHER WITH THE SCREWS SINCE THIS WILL DAMAGE THE BEARINGS AND CASE. – Remove 750.29.080.050.

6-4 – Mount all engine case screws (see photo for lengths) in a crosswise direction and tighten to 10 Nm. M6x25 M6x30

NOTE: mount the M6x25 screw in the oil filter housing with a new copper washer. M6x70

M6x30

M6x30

M6x30

M6x30 M6x70

M6x30 M6x30 M6x30

M6x30 M6x30

– 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.

Art.-No. 3.206.045-E

2 1

– Mount the lock ring 3 and washer for the countershaft.


3

– Mount new O-rings in the oil screen 4 and plug. – Insert the oil screen in the plug, screw in the plug (A/F 13 mm) and tighten to 15 Nm. NOTE: the two oil screens and plugs are identical

4

6-5 Mounting the oil pumps

B A

B A

NOTE: – The outer rotors for both oil pumps are marked with an A on the inside that is no longer visible when mounted. – The inner rotors for both oil pumps are marked with a B on the outside that is still visible when mounted. – The oil pump cover, oil pump gears, spacing washers, screws and needle rollers are 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 covers.

– Mount both oil pumps.

2 1 – Mount both oil pump covers 3, lock the screws (AH M5x12) with Loctite 243 and tighten to 6 Nm.

4

3

– Slide on the spacing washers, insert the needle rollers 4.

4

3

– Mount the oil pump gears 5, slide on the spacing washers and mount the lock rings 6. – Check the oil pump gears for smooth operation.

6 5

6-6 Mounting the shift mechanism – Mount the locking lever 1 with washer 2, sleeve 3 and spring 4, lock the screw with Loctite 243 and tighten to 10 Nm.

5 2 1

1

3

4

– Press the locking lever away from the shift drum and mount the shift lock 5. NOTE: the flat areas on the shift lock are not symmetrical. – Lock the screw 6 (AH 5 mm) on the shift lock with Loctite 243 and tighten to 10 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.

Art.-No. 3.206.045-E

– Mount the shift lever and shift through all gears while you turn the main shaft; remove the shift lever again.

6 7

8 Mounting the starter drive – Slide both needle bearings 9 onto the crankshaft. – Mount the shaft key bk.


– Mount the needle bearing bl on the starter idler gear bearing bolt.

bl

bm

bk

9 bn

– Mount the freewheel gear bm in the primary pinion bn, turning the primary pinion in a clockwise direction (see photo), making sure it does not jam.

6-7 – Simultaneously slide the primary pinion and freewheel gear 1 onto the crankshaft and the starter idler gear 2 onto the bearing bolt, allowing the starter idler gear to engage in the freewheel toothing. – Turn the primary pinion until the shaft key engages.

2 1 – Slide 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.

3 4 Mounting the clutch and primary pinion – Insert the pressure piece 5 and pushrod in the input shaft.

6

– Slide the washer 6 onto the input shaft.

5 – Slide the outer clutch hub 7 onto the main shaft.

7

NOTE: turn the oil pump gears and outer clutch hub back and forth to allow the teeth to engage. – Insert the needle bearing 8.

8

6-8 – Place the half disks 1 in the groove of the input shaft.

1

2 2

– Slide on the stepped disk 2.

– 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. Art.-No. 3.206.045-E

NOTE: make sure the upper clutch disk is offset by one meshing.


3

– Hold the primary pinion with special tool 750.29.081.000 3 while you apply Loctite 243 to the nut (A/F 27 mm, LH thread), mount and tighten to 100 Nm.

– Mount a new lock washer and screw on the nut. – Hold the outer clutch hub with special tool 750.29.081.000 while you tighten the nut (A/F 30 mm) to 100 Nm; bend down the lock washer.

6-9 – Mounting the pressure cap 1.

2

1

– 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 2.

2 Mounting the timing chain pinion and timing chain – Mount the shaft key. – Heat the timing chain pinion 3 to approx. 150° C and slide onto the crankshaft with the larger chamfer first. – Mount the lock ring 4.

5

6 3

4

– Mount the pulse generator 5, lock the screws (M6x15) with Loctite 243 and tighten to 10 Nm. – Apply Loctite 5910 (584.29.059.200) to the cable guide 6 and press into the opening.

– Thread the timing chain and position it on the timing chain pinion.

8 9 7

bl

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 pulse generator in the clip's cable duct. – Lower the tensioning rail 8 into the chain tunnel, tilt slightly as shown in the photo and insert the sleeve 9 in the clip.

– Lower the guide rail bk into the chain tunnel and insert the sleeve bl in the clip.

bk

– Apply Loctite 243 to the screws bm (M6x30) for the timing chain guide and tighten to 10 Nm. !

bm bm

CAUTION

!

MAKE SURE NO LOCTITE 243 DRIPS BETWEEN THE TIMING CHAIN GUIDES AND THE SLEEVES SINCE IT WILL CAUSE THE TIMING CHAIN GUIDES TO LOCK AND BREAK. – Make sure both rails operate smoothly.

6-10 Mounting the rotors

1 2

– Check the distance between the pulse generator and the rotor: 0.7 mm; if the distance deviates, loosen both screws 3, correctly position the sensor 4 and tighten the screws to 10 Nm.

3 3

– Slide the rotor 1 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 2 while you tighten the nut (A/F 27 mm) to 100 Nm.

4

Art.-No. 3.206.045-E

Mounting the piston, cylinder and cylinder head

5

– Liberally oil special tool 750.29.015.102 5 and piston (including the piston rings), push the piston into the special tool as far as possible without using force. The piston will protrude a few millimeters on the other side.

6

! THE

CAUTION

!

PISTON RINGS SHOULD NOT PROTRUDE FROM THE SPECIAL TOOL.

– Mount the piston and special tool on the liberally oiled cylinder and slide in the piston. NOTE: – if the parts are well-oiled, you will be able to push the piston into the cylinder with your finger. – The arrow 6 on the piston will point towards the front, i.e. the exhaust end.


7

7

– Apply a thin coat of Loctite 5910 (584.29.059.200) on the housing joints 7. – Mount a new cylinder base gasket.

– Only push the piston out of the bottom of the cylinder far enough to allow the piston bolt to be inserted. NOTE: – push the piston bolt into the conrod bearing as gently as possible. – Cover the engine case with a cloth or paper towel to prevent the piston bolt lock ring from falling in while being mounted.

6-11 – Mount the piston bolt lock ring: attach the lock ring (see photo showing the 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. NOTE: make sure the lock ring is correctly positioned in the groove.

2

– Slide the cylinder onto the engine case, apply Loctite 243 to the screw 1 (M6x25) and tighten to 10 Nm. – Mount a new cylinder head gasket 2 and mount any dowel pins previously removed. NOTE: make sure the locating tabs 3 on the timing chain guide engage in the recess in the chain tunnel.

3 1

– Mount the cylinder head and the oiled new cylinder head screws.

B

C

D 4

A

NOTE: always replace the cylinder head screws. – Tighten the cylinder head screws (A/F 14 mm or AH 8 mm) in 4 stages in a crosswise direction, starting with the left screw on the intake side (tightening order A, B, C, D) 1st stage: 15 Nm, 2nd stage 30 Nm, 3rd stage: 45 Nm, 4th stage 60 Nm – Apply Loctite 243 to both screws 4 (M6x30) and tighten to 10 Nm.

4 Moving the engine to TDC – Move the crankshaft until the piston is in the top dead center position. – Tighten the engine locking screw 0113 080802 5 and make sure the engine is locked.

5

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 1 of the 3 holes must be in the upper position.

1 – Push the camshaft into the bearing seats. NOTE: make sure the rocker arms rest on the valves, otherwise they will block the camshaft.

NOTE: if the timing chain is correctly mounted, the middle hole will be aligned directly over the hole 2 for the camshaft retaining bracket screw.

Art.-No. 3.206.045-E

3

– Mount the camshaft retaining bracket 3 in the camshaft groove, apply Loctite 243 to the screw (M6x12) and tighten to 10 Nm.

2

Mounting the chain tensioner


4

– Compress the chain tensioner 4 down to the first notch and, holding it in this position, slide it into the hole in the cylinder head. NOTE: – Checking and locking the chain tensioner: see Chapter 5. – The piston 5 should protrude approx. 3 mm from the chain tensioner.

5 – Mount the plug 6 (A/F 19) with a new seal ring and tighten to 25 Nm. – Hold the plug (A/F 19) while you remove the screw 7 (A/F 17).

7 6

6-13 – Use special tool 773.29.051.000 1 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. – Mount the screw on the chain tensioner again and tighten to 10 Nm. NOTE: check by pressing against the chain tensioner rail; the chain tensioner should lock, ensuring that the timing chain retains its tension if the engine is started without sufficient oil pressure.

1

!

CAUTION

!

THE CHAIN TENSIONER IS NOT LOCKED AS DESCRIBED IN CHAPTER 5 AND RELIEVED AFTER MOUNTING, THE TIMING CHAIN WILL JUMP WHEN THE ENGINE IS STARTED AND RESULT IN ENGINE DAMAGE.

IF

– Unscrew the engine locking screw 773.29.010.000, turn the crankshaft 2 turns in a counterclockwise direction and screw the engine locking screw back in again; make sure the engine is locked.

3

– Check the position of the camshaft gear: the mark on the camshaft 2 must be in alignment with the mark on the camshaft retaining bracket. NOTE: the mark on the camshaft retaining bracket points to the center of the screw 3.

2

Right side of the engine – Screw in the temperature sensor 4 (A/F 19 mm, tightening torque 12 Nm) and spark plug 5 (750.29.172.000, tightening torque 17 Nm).

5 4

– Mount the centering sleeves and a new clutch cover gasket. – Mount the clutch cover. – Mount the screws (see photo lengths) and tighten to 10 Nm.

M6x25

M6x25

M6x25

M6x25

M6x35

M6x30

M6x30 M6x25

M6x25 M6x25 M6x25

M6x25

for

6-14 – Slide the washer 1 onto the water pump shaft. – Slip on the water pump wheel 2, apply Loctite 243 to the screws (M6x15) 3 and tighten to 10 Nm.

1

– Mount a new gasket in the water pump cover.

2

3

Art.-No. 3.206.045-E

– Mount the water pump cover, mount the screws (M6x30) and tighten to 10 Nm.

5

4

– 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. NOTE: both oil filter covers are identical. – Move the engine back into a vertical position and screw in the oil filling plug 6.

6 – Mount a new thermostat 7 with a new gasket.


– Position the thermostat connection 8 with collar bushings, apply Loctite 243 to the screws (M6x20) and tighten to 10 Nm.

7

8

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 1.

2

1

– Mount the oil filter cover 2 with a new O-ring, mount the screws (M5x16) and tighten to 6 Nm. NOTE: both oil filter covers are identical. – Move the engine back into a vertical position.

– Mount new O-rings on the oil screen 3 and plug. – Slide the oil screen on a pin wrench. Insert the pin wrench through the opening in the bore on the opposite engine 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.

3

!

CAUTION

!

AN

INCORRECTLY MOUNTED OIL SCREEN LOSES ITS FILTERING EFFECT AND LEADS TO EXCESSIVE ENGINE WEAR.

NOTE: both oil screens and plugs are identical.

– Insert both contact springs 4 in the bores.

5

– Mount both contact bolts 5 and a new O-ring 6.

6 5 4 – Mount the gear sensor 7, apply Loctite 243 to the screws (AH M5x12) and tighten to 5 Nm.

8

M6x25

– Mount the centering sleeves, mount a new gasket and mount the generator cover. Tighten the screws (see photo for lengths) to 10 Nm, applying Loctite 243 to the screw 8.

M6x30

M6x30

M6x25 M6x25

7

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 1 (M6x20) and tighten to 10 Nm.

– Unclamp the engine.


Art.-No. 3.206.045-E

3

9-1

TROUBLE SHOOTING INDEX


Art.-No. 3.206.045-E

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9

9-2 TROUBLE

CAUSE

REMEDY

Engine does not start when the starter button is actuated

Operating error

Turn on the ignition, switch the gear to neutral and switch the emergency OFF switch on, do not accelerate while starting the engine

Discharged battery

Recharge the battery and investigate the causes for discharging

Blown fuse

Replace fuse 1, 2, 3 or 4 in the fuse box

Main fuse is blown

Remove the seat, move the tank back and replace the main fuse

Defect ignition lock or emergency OFF switch

Check ignition lock and emergency OFF switch

Defect safe-starting system.

Repair safe-starting system

A gear is engaged

Shift the transmission to neutral

A gear is engaged and the side stand is still folded down

Shift the transmission to neutral



Engine cranks with gear engaged.



Engine cranks but doesn’t start.

Operating error

Pay attention to starting off information (see driving instructions)

Blown fuse for the fuel pump

Replace fuse 4

Fuel line connection not attached

Connect the fuel line


Art.-No. 3.206.045-E

The engine cranks only with pulled clutch lever

The plug and socket connector on 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 power

Air filter/fuel filter heavily soiled

Have the air filter/fuel filter replaced

Error in the injection system


Engine overheats

Insufficient cooling liquid

Refill cooling liquid (see maintenace work), check cooling system for leaks

Radiator fins are extremely dirty

Clean radiator with water jet

Foam forms in cooling system

Replace cooling liquid, use antifreezer with brand name

Radiator hose is kinked or damaged

Run the radiator hose correctly or replace

Thermostat defective

Check the thermostat (opening temperature 70°C, 158°F) or replace

Blown fan fuse

Replace fuse 5

9-3 TROUBLE

CAUSE

Engine overheats

Defect fan or thermoswitch for fan Repair system

REMEDY

Air in the cooling system

Bleed the cooling system

FI lamp is blinking / lights up

Error in the injection system


Engine stalls while driving

No fuel

Refuel

The fuse for the ignition or fuel Replace fuse 1, 2 or 4 pump is blown High oil consumption

Headlight and position light fail

Engine oil level too high

Check engine oil level when the engine is warm; correct if necessary

Engine oil too thin (viscosity)

Use thicker engine oil; see chapter „Engine oil“

Kink in engine vent hose

Remove the seat, move the tank back and check engine vent hoses

Blown fuse

Replace fuse 7

Turn signal, brake light and horn Sicherung durchgeschmolzen do not function

Replace fuse 6

Time is not displayed or not correctly displayed

Blown fuse, thus no continuous power supply

Replace fuse 2 and set the clock

The battery is discharged

The ignition (power consumer) hasn’t been switched off

Recharge the battery according to the relevant instructions

The battery isn’t charged by the generator

Check voltage regulator and generator.

No values are visible in the combined instrument display.

Blown fuse

Replace fuse 1

The speed indication on the combined instrument is not working

Pickup cable is damaged or contacts on the cable connector have oxidized

Check the pickup cable for damage, repair if neccessary

11-1

TECHNICAL SPECIFICATIONS INDEX

690 LC4 SUPERMOTO / SUPERMOTO PRESTIGE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 TIGHTENING TORQUES ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6


Art.-No. 3.206.045-E

TOLERANCES, MOUNTING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

11

11-2

TECHNICAL SPECIFICATIONS – ENGINE


Art.-No. 3.206.045-E

ENGINE 690 LC4 2007 Design

Single-cylinder, 4-stroke Otto engine with balancer shaft

Displacement

654 cm3

Bore / Stroke

102 / 80 mm

Compression ratio

11,8 : 1

Fuel

unleaded fuel with at least RON 95 (USA: Premium PON 91)

Valve timing

4 valves OHC, roller rocker arms

Valve diameter Intake

40 mm

Valve diameter Exhaust

34 mm

Valve clearance, cold Intake

0,07 - 0,13 mm

Valve clearance, cold Exhaust

0,07 - 0,13 mm

Crankcase bearing

Two cylinder roller bearing

Conrod bearing

Needle bearing

Piston pin bearing

Bronze bushing

Piston

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

Quantity of engine oil

approx. 2 liters)

Clutch

Straight-toothed spur wheels 36 : 79

Primary drive

36:79

Transmission (claw shifted)

6-speed

1. gear

14 : 35

2. gear

16 : 28

3. gear

21 : 28

4. gear

21 : 23

5. gear

23 : 22

6. gear

23 : 20

Mixture preparation

electronically controlled gasoline injection

Ignition system

breakerless transistorized electronic ignition system with digital ignition advance

Alternator

12V 224W at 5000 rpm

Spark plug

NGK LKAR8AI-9

Electrode distance

0,9 mm

Cooling system

liquid cooled

Cooling liquid

1.2 liter, 50% antifreeze, 50% distilled water, at least –25°C (-13°F)

Starting aid

electric starter

11-3

TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS

690 SUPERMOTO 2007

Rahmen

690 SUPERMOTO PRESTIGE 2007 Chromoly trellis frame, powder-coated WP Suspension – Up Side Down 4860 ROMA

Fork Spring travel front Rear suspension

210 mm WP Suspension - 4618 shock absorber - PRO-LEVER relay lever

Spring travel rear Front brake Rear brake Authorized front tires *

Air pressure Authorized rear tires *

Air pressure

210 mm 4-piston fixed radial caliper, brake disc Ø 320 mm single-piston floating caliper, brake disc Ø 240 mm BRIDGESTONE Battlax BT090F

METZELER Sportec M3 Front

120/70 R17 M/C 58H

120/70 ZR17 M/C 58W

Road, driver only................................................2.0 bar Road, with passenger / maximum payload ............2.0 bar BRIDGESTONE Battlax BT090R PRO

METZELER Sportec M3

160/60 R17 M/C 69H

160/60 ZR17 M/C 69W

Road, driver only................................................2.0 bar Road, with passenger / maximum payload ............2.2 bar

Fuel tank capacity Lighting

Battery

13 liters, 2.5 liters Reserve high beam + low beam ..................................H4 12V 60/55W (socket P43t) position light front.............................................12V 5W (socket W2.1x9.5d) Instrument lights + indicator lamp ..........................................................LED position light rear ..................................................................................LED stoplight ..............................................................................................LED licens plate illumination ....................................12V 5W (socket W2.1x9.5d) flashers ................................................................12V 10W (socket BA15s) maintenance-free battery 12V / 8.6 Ah

Gear ratio – rear wheel Chain Steering head angle Wheel base

17:41 5/8 x 1/4” X-Ring 63,5° 1472 ± 15 mm

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

11-4 FORK

690 SUPERMOTO

690 SUPERMOTO PRESTIGE

Type

14.18.7C.07 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



Spring

65 - 230

65 - 230

Spring preload

12 mm (0.472 in)

12 mm(0.472 in)

Basic Setting

Driving Sport

Maximum Payload

-

20

15

10

10

10

20

15

10

10

Driving Sport 10

Basic Setting 15

Driving Sport

Maximum Payload

Driving Comfort

Basic Setting

Driving Sport

Maximum Payload

BASIC SETTING SHOCK ABSORBER WP 4618

SUPERMOTO PRESTIGE

Basic Setting

SUPERMOTO

Compression adjuster Low Speed (clicks)

-

-

-

-

20

15

10

10

-

-

-

-

2

1,5

1

1

Rebound adjuster (clicks)

20

15

10

10

20

15

10

10

Spring preload (mm)

12

12

12

12

12

12

12

12

Compression adjuster High Speed (turns)


20

Driving Comfort

Art.-No. 3.206.045-E

Rebound adjuster (clicks)

Driving Comfort

Compression adjuster (clicks)

Driving Comfort

BASIC SETTING FORK WP 4860 ROMA

SUPERMOTO PRESTIGE

Maximum Payload

SUPERMOTO

11-5

TIGHTENING TORQUES – ENGINE HH screws for ignition cover

M6

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

Plugs for oil bore in oil cooler

M10x1

Plug for drain bore in water pump

M10x1

Oil jet (piston cooling)

M6x0.75

Oil jet (conrod lubrication)

M4

Threaded sleeve (engine vent)

M16x1.5

Loctite 243 + 10 Nm

Loctite 243 + 9 Nm 15 Nm 15 Nm Loctite 648 + 6 Nm Loctite 648 + 2 Nm Loctite 243 + 25 Nm

AH plug for crankshaft fixation

M8

20 Nm

AH screw to fasten diaphragm plate/diaphragm

M3

Loctite 243

AH screws for oil pump cover

M5

Loctite 243 + 6 Nm

Screws for bearing retainers

M5

Loctite 648 + 5 Nm

HH nut for clutch drive

M20x1.5

HH screws for slave cylinder

M6

Loctite 243 + 10 Nm

HH screw for locking lever

M6

Loctite 243 + 10 Nm

AH screw for shift lock

M6

Loctite 243 + 10 Nm

HH screw for gear sensor

M5

HH nut for primary gear

M20x1.5 LH thread

HH nut for ignition rotor

M18x1.5

AH screws to fasten stator in ignition cover

M6

HH screws for starter

M6

HH screws for cylinder head

M10

Loctite 243 + 100 Nm

Loctite 243 + 5 Nm Loctite 243 + 100 Nm 100 Nm Loctite 243 + 10 Nm Loctite 243 + 10 Nm 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 chamber)

M6

Loctite 243 + 10 Nm

AH screws for front/rear rocker arm shafts

M6

12 Nm

HH screw for camshaft retaining bracket

M6

Loctite 243 + 10 Nm

Spark plug

M12x1.25

AH screw to fasten vent cover

M5

Loctite 243 + 3 Nm

17 Nm

Stud for exhaust flange

M8

Loctite 243 + 10 Nm

CU nut to fasten exhaust flange

M8

20 Nm

AH screw for decompression bearing bolt

M6

Loctite 243 + 3-4 Nm

HH screw for water pump wheel

M6

Loctite 243 + 10 Nm

HH screw for thermostat case

M6

Loctite 243 + 10 Nm

Temperature sensor on cylinder head

M12x1.5

12 Nm

HH screw for timing chain tensioner (plug)

M20x1.5

25 Nm

HH screw for timing chain tensioner (release screw)

M10x1

10 Nm

HH screw for guide rail

M6

Loctite 243 + 10 Nm

HH screw for tensioning rail

M6

Loctite 243 + 10 Nm

AH plug for oil thermostat

M24x1.5

15 Nm

Oil plug at oil screen

M20x1.5

15 Nm

Oil plug with magnet

M12x1.5

20 Nm

Plug for pressure relief valve

M12x1.5

20 Nm

HH screw for pulse generator

M6

Loctite 243 + 10 Nm

HH rear sprocket nut (A/F 27)

M20x1.5

Loctite 243 + 60 Nm

HH screw for shift lever

M6

Loctite 222 + 10 Nm

Gemi hose clamp (intake)

M4

1.5 Nm

Other engine screws

M5

6 Nm

M6

10 Nm

11-6


Art.-No. 3.206.045-E

TIGHTENING TORQUES – CHASSIS Screw for side stand switch Spoke nipple Screw for fuel pump, pressure regulator Screw for fuel level sensor Screw for foot brake pedal surface Screw for plastic clamp brake line fork leg Screw for heat protector on exhaust Screw for side cover Screw for seat lock Screw for starter cable - starter Pushrod ball joint foot brake cylinder Remaining screws for tank Screw for compensating tank rear wheel brake Screw for battery rack, control unit holder Screw for fuel cock Screw for front/rear brake disk Screw for foot brake cylinder Screw for horn Screw for license plate holder Screw for lower radiator mount Screw for magnetic side stand holder Screw for rectifier regulator Screw for headlight mask Screw for side stand bracket Screw for SAS valve Nut for rear sprocket screw Nuts for header - cylinder head

M4 M4,5/M5 M5 M5 M5 M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M8 M8

Screw for silencer exhaust clamp Screw for header exhaust clamp Screw for side stand spring bracket Screw for rear footrest support Screw for rear footrest bracket Screw for upper triple clamp Screw for lower triple clamp Screw for fork stub Screw for grip Screw for steering stem clamping Screw for header - silencer Screw for handlebar clamp Screw for upper subframe Screw for side stand bracket Screw for tank bearing Screw for linkage bracket, front engine holder Screw for front/rear brake disk Engine mount screws Screw for upper/lower shock absorber Screw for handlebar mount Screw for side stand Screw for front brake caliper Screw for lower subframe Lambda probe Nut for frame - connecting lever - rocker arm - swinging fork Nut for swing arm pivot Nut for engine sprocket Screw for steering head Adjusting ring for swing arm support Screw for front wheel spindle Nut for rear wheel spindle Remaining chassis screws

M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8x1,25 M10 M10 M10 M10 M10x1,25 M10x1,25 M12x1,25 M14x1,5 M16x1,5 M20x1,5 M20x1,5 M24x1,5 M24x1,5 M25x1,5 M5 M6 M8 M10 M6 M8 M10

Remaining chassis screws

Loctite 243 + 2 Nm 5 Nm 4 Nm 3 Nm Loctite 243 + 6 Nm 2 Nm Loctite 243 + 5 Nm 2 Nm Loctite 222 + 3 Nm 3 Nm Loctite 243 + 10 Nm 6 Nm 5 Nm 3 Nm 6 Nm Loctite 243 + 14 Nm Loctite 243 + 10 Nm Loctite 243 + 6 Nm 8 Nm 5 Nm Loctite 243 + 10 Nm 8 Nm 5 Nm Loctite 243 + 10 Nm 6 Nm Loctite 243 + 35 Nm copper paste + 25 Nm evenly, do not bend washer 25 Nm copper paste + 25 Nm Loctite 243 + 25 Nm 25 Nm Loctite 243 + 25 Nm 12 Nm 15 Nm 15 Nm 6 Nm 20 Nm copper paste + 25 Nm 20 Nm Loctite 243 + 35 Nm Loctite 243 + 25 Nm 15 Nm Loctite 243 + 25 Nm Loctite 243 + 30 Nm Loctite 243 + 45 Nm Loctite 243 + 45 Nm 20 Nm Loctite 243 + 35 Nm Loctite 243 + 45 Nm Loctite 243 + 45 Nm 24,5 Nm 100 Nm 100 Nm Loctite 243 + 80 Nm 12 Nm 25 Nm 40 Nm 90 Nm 4 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm

11-7

TOLERANCES AND FITTING CLEARANCE COMPONENT Valves

Valve springs Camshafts/cylinder head

Cylinder

Piston

Piston ring

Crankshaft/conrod

Balancer shaft Oil pressure Oil consumption Oil pumps

Bypass valve Clutch

Thermostat/radiator

Transmission

MEASUREMENT/TEST . . . . . . . . . . . . . . . . . . . . . . .SETPOINT VALUE .TOLERANCE LIMIT Valve clearance (at 20ºC) intake . . . . . . . . . . . . . . . . 0.07 mm - 0.13 mm Valve clearance (at 20ºC) exhaust . . . . . . . . . . . . . . 0.07 mm - 0.13 mm Valve shaft runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm Sealing seat width, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.60 mm Sealing seat width, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm Valve disk runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm Valve guide, inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 6.05 mm Valve shaft, outer diameter, intake . . . . . . . . . . . . .5.961 mm - 5.975 mm . . .min. 5.93 mm Valve shaft, outer diameter, exhaust . . . . . . . . . . . .5.946 mm - 5.960 mm . . .min. 5.93 mm length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . .new 42.85 mm . . . . . .min. 42.3 mm spring washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . new 2.5 mm . . . . . . . .min. 2.4 mm Camshaft bearing journal (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 39.95 mm Camshaft bearing journal (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 17.96 mm Cylinder head distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.15 mm Size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.000 mm – 102.012 mm Size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.013 mm–102.025 mm .max.102.04mm Cylinder distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.10 mm Size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.955 mm – 101.965 mm Size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.966 mm – 101.975 mm Mounting clearance . . . . . . . . . . . . . . . . . . . . .min. 0.03 mm - max. 0.10 mm Compression ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.8 mm Oil scraper ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.0 mm Width of piston ring groove - 1st ring (L-ring) . . . . . .0.91 mm - 0.93 mm . . . . .max. 1.0 mm Width of piston ring groove - 2nd ring (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 Lateral runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm Outer crankshaft web dimensions . . . . . . . . . . . . . .71.95 mm - 72.05 mm Axial clearance for crankshaft . . . . . . . . . . . . . . . . .0.15 mm - 0.25 mm Bearing clearance for conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 mm Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 mm - 0.20 mm measured at the right oil filter cover with the engine at service temperature .min. 0.5 bar at 1600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.8 lt /1000 km Clearance between inner and outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.2 mm Clearance between outer rotor and case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.2 mm Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 mm - 0.08 mm Length of spring, unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 25 mm Thickness of lining disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.5 mm Thickness of steel disks . . . . . . . . . . . . . . . . . . . .1.45 mm - 1.55 mm . . . . min. 1.35 mm Length of clutch springs, unloaded . . . . . . . . . . . . . . . neu 33.5 mm . . . . . . min. 31.5 mm Opening temperature of thermostat . . . . . . . . . . . . . . .68 ºC - 72 ºC Opening stroke of thermostat . . . . . . . . . . . . . . . . . . . .min. 6 mm Discharge pressure of radiator cap . . . . . . . . . . . . . . . .max. 1.4 bar Switch-on temperature of radiator fan switch . . . . . . . . . .102 ºC Axial clearance of the mainshaft . . . . . . . . . . . . . . . 0.1 mm - 0.4 mm Run out of the mainshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.025 mm Clearance between shift fork and groove . . . . . . . . .0.49 mm - 0.75 mm Width of shift fork groove . . . . . . . . . . . . . . . . . . .5.55 mm - 5.6 mm Thickness of shift fork . . . . . . . . . . . . . . . . . . . . .4.85 mm - 4.95 mm

12-1

PERIODIC MAINTENANCE SCHEDULE INDEX


Art.-No. 3.206.045-E

690 LC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2

12

12-2

PERIODIC MAINTENANCE SCHEDULE

BRAKES

ADD-ON-PARTS

FUEL INJECTION

ENGINE

690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007 A clean motorcycle can be checked more quickly which saves money!

1st Service after 1000 km (621 miles)

Change engine oil, coarse and fine filter

z

z

z

Clean oil screens and drain plug magnet

z

z

z z

Renew spark plug

z

Check and adjust valve clearance Check engine fastening bolts for tight fit

z

z

z

Check all engine bolts accessible from the outside for tight fit

z

z

z

Check rubber boots for cracks or leaks

z

Check fault memory with the KTM diagnosis tool

z

z

z

z

z

z

z

z

z

Replace the O-ring on the fuel hose connection and check for leaks

z

z

z

Check the wiring harness on the throttle body for proper installation and damage

z

Check cooling system for leaks and antifreeze protection

z

z

z

Check radiator fan for proper operation

z

z

z

z

z

z

z

z

z

z

z

Perform a status check of neutral, clutch, 2nd/3rd gear and side stand switch using the KTM diagnosis tool Make sure the fuel hose, SAS hoses and vent hoses are run correctly and check for damage

Check the exhaust system for leaks and correct suspension and the clamps for a tight fit Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Check the oil level in the hydraulic clutch reservoir

z

z

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, tell-tale lamps, speedometer illumination, horn, sidestand switch, clutch switch, emergency-off switch)

z

z

z

Make sure all bolts and nuts are tight

z

z

z

Check brake fluid level, lining thickness, and brake discs

z

z

z

Check air filter, renew if necessary, clean air filter box

z

Change brake fluid Check brake lines for damage and leaks

z

z

z

Check/adjust smooth operation, free travel of handbrake/footbrake levers

z

z

z

Check bolts of brake system for tight fit

z

z

z

Check shock absorber and fork for leaks and proper operation

z

z

z

z

z

Bleed fork legs

z

z

z

Check swinging-fork pivot

z

z

z

Check/adjust steering-head bearing

z

z

z

Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, shock absorber)

z

z

z

Check rim joint

z

z

z

Check tire condition and inflation pressure

z

z

z

Check chain, sprockets and chain guides for wear, force fit and tension

z

z

z

Check bolts on pinion and chain sprocket for locking devices and a tight fit

z

z

z

Lubricate chain

z

z

z

z

z

Clean fork dust sleeves CHASSIS

every every 5000 km 10000 km (3107 miles) or (6214 miles) or once a year every 2 years

z

WHEELS

Lubricate PRO-LEVER relay lever

Check wheel bearings and jerk damper for play

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!

12-3 690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007 ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER at least once a year Perform complete fork maintenance

every 10000 km (6214 miles) or every 2 years z z

Perform complete shock absorber maintenance Clean and lubricate steering-head bearing and sealing elements

z

Treat the electrical contacts and switches with contact spray

z

Treat battery connections with contact grease

z z

Change coolant fluid

690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007 VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC

Check oil level

before each start z

Check brake fluid level

z

Check brake pads for wear

z

Check lighting system for proper operation

z

Check horn for proper operation

z

after every cleaning

z

Lubricate actuating cables and nipples

z

Bleed fork legs

z

Art.-No. 3.206.045-E

Clean chain z

Lubricate chain Check chain tension

z

Check tire pressure and wear

z

Check coolant level

z

Check fuel lines for leaks

z

Check all control elements for smooth running

z z

Grease the hand brake lever and clutch lever


Check brake performance

every 1000 km (621 miles)

z

z

Treat exposed metal components (except for the braking and exhaust system) with wax-based anti-corrosion agents

z

Treat ignition/steering lock and light switch with contact spray

z

z

13-1

WIRING DIAGRAMS INDEX

690 LC4 SUPERMOTO


Art.-No. 3.206.045-E

EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . .13-2 START/CHARGING-/ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 LIGHTS, INSTRUMENTS, FLASHER, HORN, COOLING FAN . . . . . . . . . . . . . . . . .13-5

13

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. The 5th position is not required for connectors with less than 10 pins.

Cable colours bl: black ye: yellow bu: blue gn: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple

F

E

D

C

1

-A 1

3

-A 2 -A 3

1

C _ A C /6

C _ D K /1 8

4

6

7

fla R -X 2 00

6

/3 . D 5 /3 . D 5

5

8

9

1

A L A -P 1

2

C _ B R /4

3

/3 . C 5

dia -X 50

4

C onne c tor for optiona l a la rm s ys te m

pow-X 9

/3 . C 3

70

10,11

10 11 12 13 14 15 16 17 18

10A

-F 1

2

3

2

1

1

1 87, 190, 191

B a t-P 1

-S 2 0

54

s eat s urve illa nc e

C _ B V /2

C _ B S /2

2

-X 4 3

/2 . B 3

6 9 0 S upe rmoto 2 0 0 7

a la rm s ys te m dummy plug

3

2

1

C _ D J /1 8

4

/2 . C 3

2

fla L -X 2 00

5

32,54

C _ B K /4

12

C _ B C /6

-S 1

/2 . C 3

4

1,2

1

3 C _ E B /4

light re la y

2

6

-K 3

4

5

ba tte ry, ge ne ra tor, s ta rte r

G N D -X 8

/3 . B 3

36,37 37

-X 1 s plic e

34,35 13

s ta rt/s top s witc h

5

-M1

s ta rte r motor M

-K 1

6

4

3

1

3

6

2

C _ E B /4

powe r re la y

2

4

C _ A E /4

30 A

s ta rt re la y

4 178

38 31 31

B

-S 2

115,164

-X31

11,70

-X32

18 bl

4

1

/2 . A 5

ba tte ry

4 , 1 7 8 , 6 G N D -X 2

-G 1

-K 4

1

ignition s witc h

13,12

19 bl

9

-X33

8

-X34

21bl

20 bl

100,189

-X35

22 bl

95,188

-X36

23 bl

185

-X38

-X37

24 bl

32,31

-X39

184

25 bl

10

Antenna 27 bl

pow-X5

3

129 MAR-A2

9 190

-X40 28 bl

191

-X41 29 bl

85

-X42 30 bl

2 36

2

4

35

34

7

2

1

2

1

3 C _ E B /4

7

7

s ta rt a ux illa ry re la y

5

Art.-No. 3.206.045-E

gn

-K 2

C_BI/2

A

1

186

/3.A5 lig-X4 39

5

/2.A7 /2.D3 46

/2.E5 STR-A2 47

187 185

for optional alarm system

C_AU/2

7,8


re -wh

3

750 . 1 1. 07 5. 00 0 750 . 1 1. 076 . 0 00

-N 1

8

ma in ha rne s s -

ge ne ra tor

G

U

re gula tor-re c tifie r re -wh

gn

gn

8

3 P.

P a ge : 1

F

E

D

C

B

A

13-3

F

E

D

1

C _ A L /2

C _ A T /2

2. 2 2. 1

2

153

1

t°

C _ C M/2

-B 2

-X 3 0 0

a ir te mp. s e n s or

2

302

4

144

C _ A P /6

5

142

1

rollove r s e n s or - B 7

143

6

64

1

t°

C _ D Z /4

C _ D Y /4

2

65

he go s e n s or

L

3

4

66

-B 4

a tmos phe ric pre s s ure s e ns or

p

1

p

C _ D X /3

2

156

ma nifold pre s s ure s e ns or

3

-B 6

2

1 C _ A L /2

pic k up

C _ A T /2

1 22

-L 2

/1 . D 2 /1 . E 6

1 38, 13 9, 143 , 150

-X 1 6 s plic e

148

71

ignition c oil

+

MA R -A 2

-A 2 -A 3

-

-X 1 5 s plic e

-L 1

2

3

1

2

3

4

-A 2

5

6

7

8

1 20, 121, 155

C _ D S /4 4

2

9

C _ A R /2

1

C _ A M/2

/3 . E 2

1 3 1, 13 2

69, 72, 176, 177, 80, 106

C L U -A 2

130

-X 1 7 s plic e

-X 8 s plic e

1 87, 190, 191

6 9 0 S upe rmoto 2 0 0 7

-B 5

1

50

1 54, 123, 124, 140, 141, 144, 151, 153

147

157

124

2

121

C _ D P /3

154

49 155

70 dia-X50

/1.D3

72 67

G N D -X 8

68

/1 . E 4

127

159

126

3

-X 6 s plic e

125

53

158

1 25 , 1 57

129

-X 7 s plic e

115

150 1 66 , 1 67

2

3

-X 1 0 1

160

158

133

166

4

E FI

E F I

5

55, 56

48

-B 8 -P 1

1

C _ A R /3

1 6 0 M I L -P 1 4 7 S T R -A 2

1 6 2 T A C -P 1

2

C _ A M/3

/1 . E 7

/3 . B 3 /3 . B 3

3

-B 1 0

1

1 C _ D W /2

2

C _ A M/3

C _ A R /3

6

-Y 2 e x ha us t a ir va lve

2

/3 . B 3 /3 . D 4

/3 . C 3

3

throttle pos ition s e ns or

/3 . B 2

a c c e le ra tion pos ition s e ns or -B 1

A B S -P 1

7 5, 80, 8 3, 106 G N D -X 1 1

1 81

1 19, 145 , 163, 1 79, 69, 75, 83 G N D -P 1

52, 53, 60, 64, 67, 49

-X 3 s plic e

1 18, 165, 181

119

183

4 , 1 78 , 6

1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

135

71

136

-X 1 8 s plic e

116

149 130

/3 . B 3

120

151 65

te m-P 1

118

3

142

1

62

C _ A R /3

50

3

148

2

123

1

146

2

51

1

134 149

C _ E C /3

152

C _ A M/3

131 128

/3.B3 Neu-P1 134

N

63

3 th

162

2 nd

156

G N D -X 2

161

/1 . D 7

163

C _ D U /2

126

-S 1 1

147

-B 1 1

68

6

59

4

138

133 145

C

152

301

135

B

66

140

1

139

t°

51

-B 9 t°

47

-X 2 s plic e

136

52

ge a r pos ition s witc h

1 C _ D Q /2

inje c tion

2

-B 3

60

s ide s ta nd s e ns or

-Y 3

1

C _ A T /2

C _ A L /2

R

2

fue l le ve l s e ns or

/1 . E 6

fue -P 1

pow-X 5

1

2

3

4

-A 3

C _ D T /3 6

5

10A

10A

6

1

C _ D V /2

M

7

7

8

2

1

10A

2

1

-F 2 -F 3 -F 4

2

fue l pump

/3 . B 3

-M2

46

-X 5 s plic e

9

167

dia gnos tic

164

7

2

1

172

10A

-F 9

2

1

210

7

6

5

4

3

2

M

8

/3 . A 5

1

C _ D R /2

C _ E E /2

-M4

throttle s te ppe r motor

AC C 1

8

EPT

750 . 1 1. 07 5. 00 0 750 . 1 1. 076 . 0 00

8

ma in ha rne s s -

1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

127

c onne c tor purge va lve C _ B H /6 -X 5 0 C _ A P /6 -Y 1

180

45 48 169

wa te r te mp. s e ns or

141 59

62

44 168 128

61 165

43 61 170 171

6

211 146

5

179

174

4

177

3

161

173

2

199 168

175 173

170

174

171 199

169 175

172

176

A

63

1

3 P.

P a ge : 2

F

E

D

C

B

A

13-4

F

E

D

C

1

front brake switch

flasher right front

/2 . B 5

-B 8 -P 1

2

56

57

58

-S8

-H7

-H12

B

3

2

1

C_AH/2

2

117

C L U -A 2

116

B a t-P 1

-S 7

/2 . E 5 /2 . B 2 /2 . C 7 /2 . B 5 /2 . E 5 /2 . B 6 /1 . D 3 /2 . B 6

/1 . C 4

54

2

3

5

6

C_DI/2

7

8 9

2

4

P . light

7

2

98, 99

5

L

-X 1 4 s plic e

93, 94

-X 1 3 s plic e

3

R

6

3

9

2

7 9, 104, 105

1

fla s he r re la y

G -K 5

C _ A H /2

1

87, 89

1 C _ A I /2

diode

2

-X 4 s plic e

-V 1

-X 1 2 s plic e

C _ A Y /1

1 82

-X 5 1

39

AC C 1

1

1

86

10A

15A

2

M

C _ B L /2

C _ C D /2

1

2

1

-M3

/1 . D 2

/1 . D 2

c ooling fa n

2

10A

2

-F 5 -F 6 -F 7

4

5

ins trume nts -ta c home te r

1 07, 108, 113

lig-X 4

C _ A Y /1

/1 . E 5

83, 214, 215 84, 102, 103, 112, 114, 117, 101 G N D -X 1 1 7 5, 80, 8 3, 106

-X 1 1 s plic e

/2 . B 6 -X 1 0 s plic e

9 5, 92

1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22 23 24 25 26 27 28 29 30 31 32

be a m horn fla s he r s witc h

LO

C _ B D /1 2

C _ A D /1 2

1

HI

183

8

184

1 81

A B S -P 1

A L A -P 1

160

G N D -P 1

180 1 32

fue -P 1 M I L -P 1

159

4

N e u-P 1

te m-P 1

T A C -P 1 1 6 2

55

1

107

C _ E D /3 2

110

6 9 0 S upe rmoto 2 0 0 7

/2 . D 4

99

103

1 12

1 11

109

113

114

94

1 02

88

87

55, 56

84

1

C_CX/2

3

2

C_CX/2

position light

headlight

flasher left front

clutch switch

93 98

111

110,109

C _ A R /3

82

C_AK/2

1

C_CW/2

C_BW/3

C_CW/2

101

C _ A M/3

108

2

1

2

C_AT/2

-H11

-H6

-S9

100,97 91

-P 1

92

G

97

-B 8

90

42 104

/2 . B 8

89

40 73 73

10A

-F 8

212 2

1

fla R -X 2 00

6

-H 5

t

C _ A V /2

1

106

6

-S 5

189

105 188

1

1

2

C _ C R /1

ho r n

-X 2 2

te mpe ra ture s witc h

2

1

C _ C R /1

a ditiona l c urre nt c onne c tion A C C 1 -X 2 1

81, 77

9 5, 188

fla L -X 2 00 1 00 , 1 89

7 6, 85, 86

-X 9 s plic e

213

multi- func . -digita l-s pe e dome te r

90

pow-X9 85

/1.E3

s pe e d s e ns or 211

5

74

4

75

1

2

1

1

C_AL/2

81

3

C_AZ/4

2

91

-X200 C_BK/4

-S 6

1

C _ C R /1

C _ A K /2 C _ A H /2

201

2

-X 2 4

-X 2 0 1 s plic e

204

203

2 02

1

7

7

205, 206, 207

1

C _ C R /1

a ditiona l c urre nt c onne c tion A C C 2

re a r bra k e s witc h

-X 2 3

78

41 76 74

215

A

1

2.4 2.3 2.2 2.1

213 77

214 82

1 2 3 4

205

2 02

207

203

206

201

80

C_CX/2

79

7 8, 88

C_CW/2 C_BG/3

Art.-No. 3.206.045-E

2

C_AR/3

1 2

1 2 1

3 C_CX/2

-H8 -H4

8

750 . 1 1. 07 5. 00 0 750 . 1 1. 076 . 0 00

8

ma in ha rne s s -

-H9

1 2 C_CW/2

flasher right rear rear light/ brake light -H200 licence plate lamp flasher left rear


3 P.

P a ge : 3

F

E

D

C

B

A

13-5

C_DI/2