2007 LC4 690 Repair Manual

REPAIRMANUAL2007
690 LC4
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.045-E
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 IS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
! CAUTION !
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO
DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES
UNFIT FOR TRAFFIC !
„NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS when replacing parts.
The KTM high performance engine is only able to meet user expectations if the maintenance work
is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality
assurance processes that lead to the highest possible product quality.
KTM Sportmotorcycle AG reserves the right to modify any equipment, technical specifications,
colors, materials, services offered and rendered, and the like so as to adapt them to local
conditions without previous announcement and without giving reasons, or to cancel any of the
above items without substituting them with others. It shall be acceptable to stop manufacturing a
certain model without previous announcement. In the event of such modifications, please ask your
local KTM dealer for information.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

REPLY FAX FOR REPAIR MANUALS
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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):
Name mechanic/shop foreman Company/work shop

2-1
GENERAL INFORMATION 2
INDEX
SPECIAL TOOLS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

SPECIAL TOOLS – ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . .SEE OWNER'S MANUAL
Art.-No. 3.206.045-E
Repair manual KTM 690 LC4
2-2
SPECIALTOOLS – CHASSIS
3 4
Art.-No. 3.206.045-E
1
2
FIG PART NO DESCRIPTION

1 625.29.055.000 Assembly stand
2 750.29.034.000 Adjusting nut for swingarm bearing
3 750.29.036.000 Assembly stand attachment
4 750.29.055.000 Floor jack attachment
2-3
SPECIAL TOOLS – ENGINE
FIG PART NO DESCRIPTION

1 151.12.017.000 Gear puller
2 151.12.018.100 Internal gear puller 18-23 mm
3 503.29.050.000 Bleeding syringe for hydraulic clutch
4 560.12.001.000 Universal-engine work stand
5 584.29.009.000 Magneto extractor
6 584.29.037.043 Mounting tool for inner rings of crankshaft bearings
7 584.29.059.000 Loctite 648 24 ml
8 584.29.059.200 Loctite 5910 50 ml
9 585.29.005.000 Protection sleeve for shaft seal ring of water pump
10 590.29.019.000 Valve spring mounter
11 590.29.026.006 Limit plug gauge
12 590.29.033.000 Gear puller
13 590.29.041.000 Feeler gauge for valve clearance
14 6 899 785 Loctite 243 10 ml
15 750.12.001.060 Engine holder for engine work stand
16 750.12.001.070 Engine holder for engine work stand
17 750.29.015.102 Piston ring mounting tool
18 750.29.021.000 Puller for primary gear
19 750.29.033.000 Mounting screws for Anti hopping clutch
20 750.29.035.000 Mounting tool for piston pin retainer
21 750.29.047.000 Crankshaft press tool - optional
22 750.29.047.050 Crankshaft press-out disk upper part - optional
23 750.29.047.051 Crankshaft press-out disk lower part - optional
24 750.29.048.000 Housing separating tool
25 750.29.050.000 Mounting plate for cylinder head
26 750.29.051.000 Press-out drift for camshaft bearings
27 750.29.080.000 Protection sleeve for crankshaft seal ring flywheel side
28 750.29.080.050 Protection sleeve for crankshaft seal ring clutch side
29 750.29.081.000 Gear segment
30 750.29.090.000 Protction cap for crankshaft
31 750.29.091.000 Holding wrench for flywheel
32 750.29.094.000 Oil pressure adapter
33 750.29.172.000 Spark plug wrench
34 773.29.010.000 Crankshaft locking bolt
35 773.29.051.000 Unlatcher for timing chain tensioner
36 773.29.060.000 Insert for valve spring mounter
2-4
1
2
4
3
6
7
8
10 11 12
13 14
15
16
17 18
Art.-No. 3.206.045-E
19
20
22
21
24 25
26
23
27 28 29 30
31
32 33 34 35
36
4-1
DISASSEMBLING THE ENGINE 4

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
Art.-No. 3.206.045-E
SEPARATING THE CASE HALVES, REMOVING THE CRANKSHAFT AND

TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
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.
– Remove the screws on the generator cover 2 and lift off the
generator cover. Pull out the centering sleeves, remove and discard
the gasket.
Art.-No. 3.206.045-E
– 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
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 O-
rings.
– Remove the screws and oil filter cover 2, discard the O-ring.
2 3 – 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.
4 5
Right side of the engine

– Unscrew the oil filling plug and remove.
– Remove the screws and take off the oil filter cover 6, discard the O-
7 ring.
– Pull out the oil filter 7 with circlip pliers and discard.
– 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.
– Unscrew the temperature sensor 4 (A/F 19 mm) and spark plug 5

(750.29.172.000).
5
Art.-No. 3.206.045-E
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.
NOTE: the mark on the camshaft retaining bracket is in the middle of

the screw 8.
8 – Screw on the engine locking screw 773.29.010.000, make sure the
engine is locked.
! CAUTION !
DO 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
7 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.
– 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.
– Loosen the cylinder head screws 2 (A/F 14 mm or AH 8 mm) in a

2 2 crosswise direction and remove.
NOTE: always replace the cylinder head screws.
– Lift off the cylinder head.
2 2
1 1
– Remove the cylinder head gasket 3 and discard.
3 – Remove the screw 4.
4
– Carefully pull the cylinder up, hold the piston and remove the
cylinder.
Art.-No. 3.206.045-E
– Remove the piston bolt lock 5 with a suitable tool and slide the
piston bolt 6 out of the piston, holding on to the piston.
NOTE:
– Push the 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.
6
– 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 NOTE: the sleeve 7 is inserted through the guide rail and clip.
5 – Lift off the guide rail.
6
4-8
– Hold the clip 1 while you pull out the sleeve 2 from the tensioning
rail 3.
3 – Lift off the tensioning rail.
– Remove the timing chain from the timing chain pinion and thread it
2 through to remove.
NOTE: if you plan to mount the timing chain again, mark the direction
1 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.
– Use puller 590.29.033.000 6 to pull the engine sprocket off the

crankshaft.
Art.-No. 3.206.045-E
6
Removing the clutch and primary pinion
– Clamp the anti-hopping clutch with special tool 750.29.033.000
8 7 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.
– Remove the stepped disk 3.
– Take the half disks 4 out of the groove.

3 4 4
– 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
– Mount special tool 750.29.021.000 8 on the primary pinion 9
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.
8
4-10
– Turn the freewheel gear 1 in a counterclockwise direction and
1 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.
4
Art.-No. 3.206.045-E
5
3
Disassembling the shift mechanism

– Push the shift rail 6 away from the shift lock 7 and pull out the
7 9 shift shaft 8 together with the washer mounted underneath.
– Remove the screw 9 (AH 5 mm) on the shift lock.
8
– 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
7 washer and spring.
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 – Remove both oil pump covers 4.
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.
– 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
S transmission shafts
– 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.
– Lift the crankshaft 2 out of the bearing.

Art.-No. 3.206.045-E
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.
– 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 5

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
Art.-No. 3.206.045-E
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
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
5 and the water pump shaft 2 without damaging
the case.
– 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 – 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
1 remain in the case must be pressed out with a
suitable press/drift tool.
– 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 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
6 6 when pressing in the bearings.
– Always press in bearings on the outer ring or the
6 bearings will be damaged in the process.
– Check the bearings for a tight fit when the case
has cooled.
Art.-No. 3.206.045-E
6 – Mount all bearing retainers, lock screws with
6 7 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

2 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.
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.
– Mount all bearing retainers, lock screws with Loctite 648 and
tighten to 5 Nm.
6 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 – AN
! CAUTION !
INCORRECTLY MOUNTED DIAPHRAGM SUPPORT PLATE WILL LEAD TO POOR
PERFORMANCE AND EXCESSIVE OIL CONSUMPTION OR LEAKS.
9 – 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.
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 !
NEVER LOCK THE CRANKSHAFT IN A VISE TOGETHER WITH THE CRANKPIN TO TRY
TO EXTRACT THE INNER BEARING RING. THIS WILL ONLY COMPRESS THE
2 2 CRANKSHAFT WEBS AND MAKE THE CRANKSHAFT UNUSABLE.

Art.-No. 3.206.045-E
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
5 you after mounting, the side with the chamfer 4 faces the crankshaft
web.
4
– 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.
! CAUTION !
MAKE SURE THE DOWEL DOES NOT PROTRUDE ON THE OTHER SIDE OF THE
5 CRANKSHAFT WEB.
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
1 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.
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.
– The piston is measured at the piston skirt across the piston pin, as
illustrated.
2 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

– Position the inner and outer rotors in the engine case with the marks
facing the case (not visible).
Art.-No. 3.206.045-E
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
4 3
1 3 4
3 3
1
1
5
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.
– Disconnect the automatic decompressor spring, loosen the screw 3

and remove it together with the automatic decompressor spring and
the automatic decompressor weight 4.
3
Art.-No. 3.206.045-E
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
! CAUTION !
1 IF YOU DO NOT FOLLOW THESE INSTRUCTIONS, THE TIMING CHAIN WILL NOT BE
TENSIONED CORRECTLY AND WILL SKIP, RESULTING IN ENGINE DAMAGE.
NOTE:
– The timing chain tensioner 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
2 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.
1 – Check the toothing of the sprockets 1 for chips and wear.
– Check the timing chain tensioning rail 2 for seizing marks and
damage.
– Check the timing chain guide 3 for seizing marks and damage.
2 5
– Check the timing chain clip 4 for seizing marks and damage.
3 – 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.
1
Art.-No. 3.206.045-E
5-11
2
3
4 4
3 5 5
Cylinder head
1 1 – Remove all 4 screws 1 from the rocker arm shafts 2.
1
1
– Insert an M6 screw in the rocker arm shafts and pull them out of the
cylinder head; remove the rocker arms 3.
– Remove the shims 4 from the valve spring retainers 5 and lay
them aside 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.
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).
Art.-No. 3.206.045-E
– 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.
– 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.
1
– 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 WHEN
! CAUTION !
YOU MOUNT THE ROCKER ARM SHAFTS, MAKE SURE THE SMALL HOLES 1
FACE UP.
– Mount the M6x40 screws 2 on the rocker arm shafts, mount the
M6x30 screws 3 and tighten to 12 Nm.
2
Repair manual KTM 690 LC4 Art.-No. 3.206.045-E
D
C
E
7
6
4
8
A
9
B
1
2
5
3
4
1
5-14
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 – Slide on the spring guide 8, slide the return spring
9 over the spring guide with the angled end up
9 and lift the angled end over the dolly bolt bk (see
illustration).
8 – Mount the stop disk bl.
bl
5-16
4 9
5
2 1 8
6
3
7
Art.-No. 3.206.045-E
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
– Clamp the clutch in a vise (use protective jaws), gradually loosen
2 special tool 750.29.033.000 1 and remove.
1
– Remove the clutch from the vise and place it on a clean workbench
4 with the outer hub 2 face down.
– Remove the inner hub 3 and clutch springs 4 from the outer hub.
3
– Remove the clutch disks 5 from the outer hub.
– Remove the spring ring 6 and supporting ring 7.
7 5 – Thoroughly clean all parts.
A
– Check both hubs for seizing marks and damage.
– 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.
6 – 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 NOTE: mount the spring ring with the inner edge A resting on the
1 2 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
– Slide on the inner hub 4, matching the marks.
NOTE: the outer hub has a notch 5 at the clutch spring, the arrow 6
6 on the inner hub must point to the notch.

Art.-No. 3.206.045-E
– Tightly press the two hubs together and have a helper screw on
special tool 750.29.033.000.
! CAUTION !
DO NOT TIGHTEN WITH A TOOL.
5 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
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
bs br
bq
bp bo
bn
bm
bl bk
7
6 9 8
5
4
3 2
1
Art.-No. 3.206.045-E
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
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
1 2 the primary pinion in a clockwise direction (see photo).
– You should be able to turn the freewheel gear in a clockwise
direction.
– The freewheel gear should block in a counterclockwise direction.
Replacing the freewheel

– Remove the lock ring 3 from the groove with suitable pliers.
3
– Squeeze the spreader ring 4 together with suitable pliers and

remove.
– Lift the freewheel 5 out of the primary pinion.
5 4
Art.-No. 3.206.045-E
– Check the contact area A for pressure marks; thoroughly clean the
A 6 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 6

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
Art.-No. 3.206.045-E
RIGHT SIDE OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

LEFT SIDE OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-2
Mounting the transmission shafts, assembling the engine case
1 – Mount the stop disk 1 and assemble both transmission shafts.
2 NOTE: the countershaft has a stop disk on the bearing side, the main
shaft does not.
3
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.
NOTE:
– Upper shift fork 2, middle shift fork 3, lower shift fork 4 (see
Art.-No. 3.206.045-E
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.
– 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.
2 3
– Insert the crankshaft in the bearing seat and remove
750.29.080.000.
– 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.
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 – 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.
! CAUTION !
8 7 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
NOTE: mount the M6x25 screw in the
oil filter housing with a new copper
washer.
M6x30
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.
2
Art.-No. 3.206.045-E
– 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
NOTE:
– The outer rotors for both oil pumps are marked with an A on the
inside that is no longer visible when mounted.
B B – 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
A A 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 – Slide on the spacing washers, insert the needle rollers 4.
3 4
– 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 4
1 3
– 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.
– Mount the shift lever and shift through all gears while you turn the
main shaft; remove the shift lever again.
6
Art.-No. 3.206.045-E
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 9
bk
– Mount the freewheel gear bm in the primary pinion bn, turning the
primary pinion in a clockwise direction (see photo), making sure it
bm bn 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.
– Slide on the stepped disk 2.

1 2 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.
NOTE: make sure the upper clutch disk is offset by one meshing.
Art.-No. 3.206.045-E
– 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
3 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.
1 2 – 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.
– Mount the pulse generator 5, lock the screws (M6x15) with Loctite
5 6 243 and tighten to 10 Nm.
– Apply Loctite 5910 (584.29.059.200) to the cable guide 6 and

press into the opening.
3 4
– Thread the timing chain and position it on the timing chain pinion.
8 NOTE: pay attention to the direction of travel if mounting a used timing

chain.
– Position and hold the clip 7.

9 NOTE: place the cable for the pulse generator in the clip's cable duct.
7 – 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.
bl
bk
– Apply Loctite 243 to the screws bm (M6x30) for the timing chain
guide and tighten to 10 Nm.
! 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.
bm – Make sure both rails operate smoothly.
bm
6-10
Mounting the rotors
1 – 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
2 750.29.091.000 2 while you tighten the nut (A/F 27 mm) to 100
Nm.
– Check the distance between the pulse generator and the rotor: 0.7
3 mm; if the distance deviates, loosen both screws 3, correctly
position the sensor 4 and tighten the screws to 10 Nm.
3 4
Mounting the piston, cylinder and cylinder head

– 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
5 6 possible without using force. The piston will protrude a few
Art.-No. 3.206.045-E
millimeters on the other side.

! CAUTION !
THE PISTON RINGS SHOULD NOT PROTRUDE FROM THE SPECIAL TOOL.
– Mount the piston and special tool on the liberally oiled 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.
– Apply a thin coat of Loctite 5910 (584.29.059.200) on the housing

joints 7.
7 – Mount a new cylinder base gasket.
7
– 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.
– Slide the cylinder onto the engine case, apply Loctite 243 to the
screw 1 (M6x25) and tighten to 10 Nm.
2 – 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.
NOTE: always replace the cylinder head screws.

B C – 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
D A – Apply Loctite 243 to both screws 4 (M6x30) and tighten to 10 Nm.
4 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
3 aligned directly over the hole 2 for the camshaft retaining bracket
screw.
Art.-No. 3.206.045-E
– Mount the camshaft retaining bracket 3 in the camshaft groove,

2 apply Loctite 243 to the screw (M6x12) and tighten to 10 Nm.
Mounting the chain tensioner

– 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.
4 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 !
IF 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.
– Unscrew the engine locking screw 773.29.010.000, turn the

crankshaft 2 turns in a counterclockwise direction and screw the
3 engine locking screw back in again; make sure the engine is locked.
– 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
2 of the screw 3.
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
5 Nm).
– Mount the centering sleeves and a new

clutch cover gasket.
– Mount the clutch cover.
– Mount the screws (see photo for

M6x25 lengths) and tighten to 10 Nm.
M6x25 M6x25
M6x25
M6x35
M6x30
M6x30
M6x25
M6x25
M6x25
M6x25
M6x25
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
– Mount the water pump cover, mount the screws (M6x30) and
tighten to 10 Nm.
– Lay the engine on its side, fill the oil filter housing half full with
engine oil and mount a new oil filter 4.
5 – Mount the oil filter cover 5 with a new O-ring, mount the screws
Art.-No. 3.206.045-E
4 (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
1 2 engine oil and mount a new oil filter 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
3 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.
! 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.
M6x25
8 – 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.
3
Art.-No. 3.206.045-E
9-1
TROUBLE SHOOTING 9
INDEX
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Art.-No. 3.206.045-E
9-2
TROUBLE CAUSE REMEDY
Engine does not start when Operating error Turn on the ignition, switch the gear to neutral and switch
the starter button is actuated 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 Check ignition lock and emergency OFF switch
OFF switch
Defect safe-starting system. Repair safe-starting system

The engine cranks only with A gear is engaged Shift the transmission to neutral
pulled clutch lever
A gear is engaged and the side Shift the transmission to neutral
stand is still folded down
Defect safe-starting system. Repair safe-starting system
Engine cranks with gear Defect safe-starting system. Repair safe-starting system
engaged.
Engine cranks but doesn’t Operating error Pay attention to starting off information
start. (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 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 Air filter/fuel filter heavily soiled Have the air filter/fuel filter replaced
power
Error in the injection system Error diagnosis with the KTM diagnostics tool, eliminate
error
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 Run the radiator hose correctly or replace

damaged
Thermostat defective Check the thermostat (opening temperature 70°C, 158°F)

or replace
Blown fan fuse Replace fuse 5

9-3
TROUBLE CAUSE REMEDY
Engine overheats Defect fan or thermoswitch for fan Repair system
Air in the cooling system Bleed the cooling system
FI lamp is blinking / lights up Error in the injection system Error diagnosis with the KTM diagnostics tool, eliminate
error
Engine stalls while driving No fuel Refuel
The fuse for the ignition or fuel Replace fuse 1, 2 or 4

pump is blown
High oil consumption 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
Headlight and position light Blown fuse Replace fuse 7

fail
Turn signal, brake light and horn Sicherung durchgeschmolzen Replace fuse 6
do not function
Time is not displayed or not Blown fuse, thus no continuous Replace fuse 2 and set the clock
correctly displayed power supply
The battery is discharged The ignition (power consumer) Recharge the battery according to the relevant instructions
hasn’t been switched off
The battery isn’t charged by the Check voltage regulator and generator.
generator
No values are visible in the Blown fuse Replace fuse 1

combined instrument display.
The speed indication on the Pickup cable is damaged or Check the pickup cable for damage, repair if neccessary
combined instrument is not contacts on the cable connector
working have oxidized
11-1
TECHNICAL SPECIFICATIONS 11
INDEX
690 LC4 SUPERMOTO / SUPERMOTO PRESTIGE

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
TIGHTENING TORQUES
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6
TOLERANCES, MOUNTING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

Art.-No. 3.206.045-E
11-2
TECHNICAL SPECIFICATIONS – ENGINE
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
Art.-No. 3.206.045-E
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 690 SUPERMOTO PRESTIGE 2007

Rahmen Chromoly trellis frame, powder-coated
Fork WP Suspension – Up Side Down 4860 ROMA
Spring travel front 210 mm
Rear suspension WP Suspension - 4618 shock absorber - PRO-LEVER relay lever
Spring travel rear 210 mm
Front brake 4-piston fixed radial caliper, brake disc Ø 320 mm
Rear brake single-piston floating caliper, brake disc Ø 240 mm
Authorized front tires * 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
Air pressure
Road, with passenger / maximum payload ............2.0 bar
Authorized rear tires * 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
Air pressure
Road, with passenger / maximum payload ............2.2 bar
Fuel tank capacity 13 liters, 2.5 liters Reserve
Lighting 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)
Battery maintenance-free battery 12V / 8.6 Ah

Gear ratio – rear wheel 17:41
Chain 5/8 x 1/4” X-Ring
Steering head angle 63,5°
Wheel base 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 14.18.7C.08 WP Suspension
Spring 5.2 - 430 5.2 - 430
Air chamber length 100 mm 100 mm
Fork oil SAE 2.5 SAE 2.5
SHOCK ABSORBER 690 SUPERMOTO 690 SUPERMOTO PRESTIGE

Type 15.18.9C.07 WP Suspension 15.18.7C.08 WP Suspension
Spring 65 - 230 65 - 230
Spring preload 12 mm (0.472 in) 12 mm(0.472 in)
SUPERMOTO SUPERMOTO PRESTIGE
BASIC SETTING
Maximum Payload
Maximum Payload
Driving Comfort
Driving Comfort
FORK WP 4860 ROMA
Basic Setting
Basic Setting
Driving Sport
Driving Sport
Compression adjuster (clicks) - - - - 20 15 10 10
Rebound adjuster (clicks) 20 15 10 10 20 15 10 10
SUPERMOTO SUPERMOTO PRESTIGE

Art.-No. 3.206.045-E
BASIC SETTING
Maximum Payload
Maximum Payload
Driving Comfort
Driving Comfort
SHOCK ABSORBER WP 4618

Basic Setting
Basic Setting
Driving Sport
Driving Sport
Compression adjuster Low Speed (clicks) - - - - 20 15 10 10

Compression adjuster High Speed (turns) - - - - 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
11-5
TIGHTENING TORQUES – ENGINE

HH screws for ignition cover M6 Loctite 243 + 10 Nm
Plastic screw in ignition cover M24x1.5 8 Nm
AH plug for oil bore M14x1.5 Loctite 243 + 15 Nm
AH plug for oil bore M10x1 Loctite 243 + 15 Nm
Torx plug for oil bore self-tapping Loctite 243 + 9 Nm
Plugs for oil bore in oil cooler M10x1 15 Nm
Plug for drain bore in water pump M10x1 15 Nm
Oil jet (piston cooling) M6x0.75 Loctite 648 + 6 Nm
Oil jet (conrod lubrication) M4 Loctite 648 + 2 Nm
Threaded sleeve (engine vent) M16x1.5 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 Loctite 243 + 100 Nm
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 Loctite 243 + 5 Nm
HH nut for primary gear M20x1.5 LH thread Loctite 243 + 100 Nm
HH nut for ignition rotor M18x1.5 100 Nm
AH screws to fasten stator in ignition cover M6 Loctite 243 + 10 Nm
HH screws for starter M6 Loctite 243 + 10 Nm
HH screws for cylinder head M10 oiled, 4 stages: 15/30/45/60 Nm
HH screws for cylinder head / cylinder (timing chain chamber) M6 Loctite 243 + 10 Nm
AH screws for cylinder head / housing (timing chain 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 17 Nm
AH screw to fasten vent cover M5 Loctite 243 + 3 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
TIGHTENING TORQUES – CHASSIS

Screw for side stand switch M4 Loctite 243 + 2 Nm
Spoke nipple M4,5/M5 5 Nm
Screw for fuel pump, pressure regulator M5 4 Nm
Screw for fuel level sensor M5 3 Nm
Screw for foot brake pedal surface M5 Loctite 243 + 6 Nm
Screw for plastic clamp brake line fork leg M5 2 Nm
Screw for heat protector on exhaust M5 Loctite 243 + 5 Nm
Screw for side cover M5 2 Nm
Screw for seat lock M5 Loctite 222 + 3 Nm
Screw for starter cable - starter M5 3 Nm
Pushrod ball joint foot brake cylinder M6 Loctite 243 + 10 Nm
Remaining screws for tank M6 6 Nm
Screw for compensating tank rear wheel brake M6 5 Nm
Screw for battery rack, control unit holder M6 3 Nm
Screw for fuel cock M6 6 Nm
Screw for front/rear brake disk M6 Loctite 243 + 14 Nm
Screw for foot brake cylinder M6 Loctite 243 + 10 Nm
Screw for horn M6 Loctite 243 + 6 Nm
Screw for license plate holder M6 8 Nm
Screw for lower radiator mount M6 5 Nm
Screw for magnetic side stand holder M6 Loctite 243 + 10 Nm
Screw for rectifier regulator M6 8 Nm
Screw for headlight mask M6 5 Nm
Screw for side stand bracket M6 Loctite 243 + 10 Nm
Screw for SAS valve M6 6 Nm
Nut for rear sprocket screw M8 Loctite 243 + 35 Nm
Nuts for header - cylinder head M8 copper paste + 25 Nm
evenly, do not bend washer
Screw for silencer exhaust clamp M8 25 Nm
Screw for header exhaust clamp M8 copper paste + 25 Nm
Art.-No. 3.206.045-E
Screw for side stand spring bracket M8 Loctite 243 + 25 Nm

Screw for rear footrest support M8 25 Nm
Screw for rear footrest bracket M8 Loctite 243 + 25 Nm
Screw for upper triple clamp M8 12 Nm
Screw for lower triple clamp M8 15 Nm
Screw for fork stub M8 15 Nm
Screw for grip M8 6 Nm
Screw for steering stem clamping M8 20 Nm
Screw for header - silencer M8 copper paste + 25 Nm
Screw for handlebar clamp M8 20 Nm
Screw for upper subframe M8 Loctite 243 + 35 Nm
Screw for side stand bracket M8 Loctite 243 + 25 Nm
Screw for tank bearing M8 15 Nm
Screw for linkage bracket, front engine holder M8 Loctite 243 + 25 Nm
Screw for front/rear brake disk M8x1,25 Loctite 243 + 30 Nm
Engine mount screws M10 Loctite 243 + 45 Nm
Screw for upper/lower shock absorber M10 Loctite 243 + 45 Nm
Screw for handlebar mount M10 20 Nm
Screw for side stand M10 Loctite 243 + 35 Nm
Screw for front brake caliper M10x1,25 Loctite 243 + 45 Nm

Screw for lower subframe M10x1,25 Loctite 243 + 45 Nm
Lambda probe M12x1,25 24,5 Nm
Nut for frame - connecting lever - rocker arm - swinging fork M14x1,5 100 Nm
Nut for swing arm pivot M16x1,5 100 Nm
Nut for engine sprocket M20x1,5 Loctite 243 + 80 Nm
Screw for steering head M20x1,5 12 Nm
Adjusting ring for swing arm support M24x1,5 25 Nm
Screw for front wheel spindle M24x1,5 40 Nm
Nut for rear wheel spindle M25x1,5 90 Nm
Remaining chassis screws M5 4 Nm
M6 10 Nm
M8 25 Nm
M10 45 Nm
Remaining chassis screws M6 15 Nm
M8 30 Nm
M10 50 Nm
11-7
TOLERANCES AND FITTING CLEARANCE

COMPONENT MEASUREMENT/TEST . . . . . . . . . . . . . . . . . . . . . . .SETPOINT VALUE .TOLERANCE LIMIT
Valves Valve clearance (at 20ºC) intake . . . . . . . . . . . . . . . . 0.07 mm - 0.13 mm
Valve clearance (at 20ºC) exhaust . . . . . . . . . . . . . . 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
Valve springs length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . .new 42.85 mm . . . . . .min. 42.3 mm
spring washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . new 2.5 mm . . . . . . . .min. 2.4 mm
Camshafts/cylinder head Camshaft bearing journal (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 39.95 mm
Camshaft bearing journal (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 17.96 mm
Cylinder head distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.15 mm
Cylinder 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
Piston 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
Piston ring 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
Crankshaft/conrod 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
Balancer shaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 mm - 0.20 mm
Oil pressure measured at the right oil filter cover with the engine at service temperature .min. 0.5 bar at 1600 rpm
Oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.8 lt /1000 km
Oil pumps 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
Bypass valve Length of spring, unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 25 mm
Clutch 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
Thermostat/radiator 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
Transmission 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 12

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

Art.-No. 3.206.045-E
12-2
PERIODIC MAINTENANCE SCHEDULE

1st Service every every
690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007 after 5000 km 10000 km
A clean motorcycle can be checked more quickly which saves money! 1000 km (3107 miles) or (6214 miles) or
(621 miles) once a year every 2 years
Change engine oil, coarse and fine filter z z z
Clean oil screens and drain plug magnet z z z
ENGINE
Renew spark plug z

Check and adjust valve clearance z
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 z
Check fault memory with the KTM diagnosis tool z z z
FUEL INJECTION
Perform a status check of neutral, clutch, 2nd/3rd gear and side stand z z z
switch using the KTM diagnosis tool
Make sure the fuel hose, SAS hoses and vent hoses are run correctly and z z z
check for damage
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 z z
and damage
Check cooling system for leaks and antifreeze protection z z z
Check radiator fan for proper operation z z z
Check the exhaust system for leaks and correct suspension and the z z z
clamps for a tight fit
Check actuating cables for damage, smooth operation, and kink-less z z z
ADD-ON-PARTS
arrangement, adjust and lubricate

Check the oil level in the hydraulic clutch reservoir z z
Check air filter, renew if necessary, clean air filter box z z
Check cables for damage and kink-less arrangement z z z
Check headlamp adjustment z z z
Check electrical system for function (low/high beams, stop light, turn
indicators, headlamp, flasher, tell-tale lamps, speedometer illumination, z z z
horn, sidestand switch, clutch switch, emergency-off switch)
Make sure all bolts and nuts are tight z z z
Check brake fluid level, lining thickness, and brake discs z z z
Change brake fluid z
BRAKES
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
Clean fork dust sleeves z z
Bleed fork legs z z z
CHASSIS
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, z z z
swinging-fork pivot, reversing lever, shock absorber)
Lubricate PRO-LEVER relay lever z
Check rim joint z z z
Check tire condition and inflation pressure z z z
z z z
WHEELS
Check chain, sprockets and chain guides for wear, force fit and tension
Check bolts on pinion and chain sprocket for locking devices z z z
and a tight fit
Lubricate chain z z z
Check wheel bearings and jerk damper for play z z
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 every 10000 km
once a year (6214 miles) or every 2 years
Perform complete fork maintenance z
Perform complete shock absorber maintenance z
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
Change coolant fluid z
690 SUPERMOTO / 690 SUPERMOTO PRESTIGE 2007

VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE MECHANIC
before after every 1000 km
each start every cleaning (621 miles)
Check oil level 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
Lubricate actuating cables and nipples z
Bleed fork legs z
Clean chain z
Art.-No. 3.206.045-E
Lubricate chain z z
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
Grease the hand brake lever and clutch lever z
Check brake performance z z
Treat exposed metal components (except for the braking and exhaust z
system) with wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray z
13-1
WIRING DIAGRAMS 13
INDEX
690 LC4 SUPERMOTO
EXPLANATION OF CONNECTORS, CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . .13-2

START/CHARGING-/ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3
EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
LIGHTS, INSTRUMENTS, FLASHER, HORN, COOLING FAN . . . . . . . . . . . . . . . . .13-5
Art.-No. 3.206.045-E
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
1 2 3 4 5 6 7 8
A A
gn
ignition s witc h s ta rt/s top s witc h -X 1 s plic e s ta rte r s ta rt re la y ba tte ry
motor
-S 2 -S 1
-K 1 30 -G 1
-M1 M A
38
36,37
34,35
1,2
1 re gula tor-re c tifie r
-F 1 C _ A E /4 gn
C _ B C /6 C _ B K /4
4 3 2 1 gn -N 1
C _ A C /6 C _ B R /4 34 1 re -wh
10A
U
1 3 5 2 4 6 1 2 3 4 2 re -wh
4
2
5
1
2 35
C_AU/2
C_BI/2
B B
32,54
9
31
13,12
10,11
10
12
3 G
ge ne ra tor
C C
31
54 B a t-P 1
/3 . B 3
-A 2 -A 3
/2 . C 3
70 dia -X 50
D /2 . B 3 D
4 , 1 7 8 , 6 G N D -X 2
/2 . A 5
fla L -X 2 00
/3 . D 5
fla R -X 2 00
/3 . D 5
A L A -P 1
/3.A5
/2.A7
/2.D3
/2.E5
/3 . C 3
1 87, 190, 191 G N D -X 8
/2 . C 3
187
lig-X4
-X 4 3
pow-X5
STR-A2
pow-X 9
/3 . C 5
6
9
8
95,188
32,31
85
37
39
115,164
11,70
100,189
185
184
190
191
186
185
13
46
47
36
5
7
7,8
129 MAR-A2
178
2 1
-X31
-X41
-X32
-X38
-X42
-X33
-X34
-X35
-X36
-X37
-X39
-X40
C _ B S /2
C _ B V /2
4 2 1 3 4 2 1 3 4 2 1 3
E C _ E B /4 C _ E B /4 C _ E B /4
E
21bl
20 bl
23 bl
24 bl
25 bl
27 bl
28 bl
29 bl
22 bl
30 bl
18 bl
19 bl
Antenna
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
C _ D J /1 8
C onne c tor for
C _ D K /1 8
optiona l -K 3 -K 4 -K 2
-A 1 a la rm s ys te m dummy plug -S 2 0
for optional alarm system
a la rm s ys te m
s eat light re la y powe r re la y s ta rt a ux illa ry
s urve illa nc e re la y
F F
P a ge : 1
ba tte ry, ge ne ra tor, s ta rte r ma in ha rne s s -
750 . 1 1. 07 5. 00 0
6 9 0 S upe rmoto 2 0 0 7 750 . 1 1. 076 . 0 00
3 P.
13-3
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
13-4
A A
dia gnos tic
wa te r te mp. s ide s ta nd ge a r pos ition
purge va lve c onne c tor
s e ns or C _ B H /6
s e ns or s witc h -X 2 s plic e -X 5 s plic e
-Y 1 -X 5 0 C _ A P /6 G N D -X 2 4 , 1 78 , 6 pow-X 5 46 210
-B 1 1 -S 1 1 /1 . D 7 /1 . E 6
-B 9 t° t°
1 4 6 1 19, 145 , 163, 1 79, 69, 75, 83
45
44
43
183 G N D -P 1
/3 . C 3 1 1 1 1
2 nd 3 th N -X 1 0 1 119 -F 2 -F 3 -F 4 -F 9
/3.B3
C _ D U /2
70
71
72
C _ E C /3 C _ A M/3
1 2 1 18, 165, 181
C _ A R /3 C _ A R /2 1 81 A B S -P 1
1 2 3 /3 . B 3 10A 10A 10A 10A
1 3 2 C _ A M/2 7 5, 80, 8 3, 106 G N D -X 1 1 2 2 2 2
Neu-P1
/3 . D 4
1 2 3
48
61
211
168
dia-X50
-X 3 s plic e
48 AC C 1
B /3 . A 5 B
49
50
158
157
159
150
149
151
133
134
131
te m-P 1
/1.D3
/3 . B 3
55, 56 -B 8 -P 1
/3 . B 2
52, 53, 60, 64, 67, 49
a c c e le ra tion pos ition throttle pos ition fue l le ve l fue l throttle

s e ns or s e ns or s e ns or pump s te ppe r motor
-X 1 8 s plic e
71 1 66 , 1 67 -B 1 -B 1 0 -B 3 -M2 -M4
M M
-X 7 s plic e -X 6 s plic e
1 25 , 1 57 125 -X 8 s plic e
G N D -X 8 1 87, 190, 191 69, 72, 176, 177, 80, 106 R
/1 . E 4 C _ A M/3 C _ A R /3
1 54, 123, 124, 140, 141, 144, 151, 153 C _ E E /2
66 C _ A R /3 C _ A M/3 C _ D V /2 C _ D R /2
C -X 1 6 s plic e -X 1 5 s plic e -X 1 7 s plic e 1 2 3 1 2 3 C
1 22 1 3 1, 13 2 C _ A L /2
1 2 1 2 3 4 5 6 7 8
C _ A T /2
61
62
138
135
140
139
136
141
1 38, 13 9, 143 , 150 1 20, 121, 155 130
199
174
173
175
170
171
169
172
1 2
179
180
fue -P 1
-A 2 -A 3 /3 . B 3
/1 . D 2
MA R -A 2
/1 . E 6 C L U -A 2
/3 . E 2
D D
153
152
2 1
C _ A T /2
C _ A L /2 -X 3 0 0
2. 2 2. 1
1 6 0 M I L -P 1
/3 . B 3
66
63
64
65
67
68
302
301
143
144
126
124
121
154
156
155
148
147
142
1 6 2 T A C -P 1
/3 . B 3
167
128
170
172
161
173
199
177
4 7 S T R -A 2
63
50
115
118
127
135
136
142
146
147
123
166
133
152
158
160
162
164
163
/1 . E 7
165
127
169
171
146
168
174
175
176
65
62
68
53
51
59
116
120
129
130
126
145
148
149
128
134
156
161
+ -
47
60
51
52
59
4 3 2 1
E 2 1 C _ D Y /4 2 1 1 2 3 4 5 6 7 8 9 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 1 2 3 4 5 6 7 8 9 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
E
C _ D Z /4 3 2 1 3 2 1 C _ A L /2 C _ D S /4 4
2 1 2 1 C _ D T /3 6
C _ C M/2 6 5 4 C _ D W /2 C _ D Q /2
C _ D P /3 C _ D X /3 C _ A T /2
C _ A P /6
-A 2 -A 3
rollove r t°
t° -B 2 L p -B 4 p -B 6
s e n s or - B 7 -B 5 -L 2 -L 1 E F I -Y 2 -Y 3
EPT
a ir te mp. he go a tmos phe ric ma nifold pic k up ignition e x ha us t a ir inje c tion
s e n s or s e n s or pre s s ure pre s s ure c oil va lve
s e ns or s e ns or
F F
P a ge : 2
ma in ha rne s s -
750 . 1 1. 07 5. 00 0
6 9 0 S upe rmoto 2 0 0 7 E FI 750 . 1 1. 076 . 0 00
3 P.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A a ditiona l c urre nt a ditiona l c urre nt A

s pe e d AC C 1 c onne c tion A C C 1 c onne c tion A C C 2
s e ns or multi- func . -digita l-s pe e dome te r /2 . B 8
-X 2 1 C _ C R /1 -X 2 2 C _ C R /1 -X 2 3 C _ C R /1 -X 2 4 C _ C R /1
-X 4 s plic e
-B 8 lig-X 4 39 1 1 1 1
G -P 1 /1 . E 5
211
214
213
215
40
41
42
212
C _ A Y /1
C _ A R /3 1 1 1 1
-F 5 -F 6 -F 7 -F 8
C _ A M/3 C _ E D /3 2 C _ A Y /1
-X 5 1
1 2 3 1 2 3 4 5 6 7 8 9 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
1
93
10A 10A 15A 10A
54
98
58
57
56
110
101
-B 8 -P 1 55, 56 B a t-P 1 2 2 2 2
/2 . B 5 /1 . C 4 re a r bra k e
55 1 82
s witc h
213
73
76
ho r n
104
B T A C -P 1 1 6 2 -S 6 B
2
87 /2 . E 5 -H 5
te m-P 1 159
/2 . B 2
fue -P 1 180
1
88 /2 . C 7
switch
C_AK/2
C_AH/2
N e u-P 1 1 32
front brake
/2 . B 5 1 2
M I L -P 1 160
-S8
/2 . E 5
-H8
1 81
81
82
A B S -P 1
/2 . B 6 -X 1 2 s plic e C _ A K /2
A L A -P 1 184 C _ A H /2
2 02
1
/1 . D 3
2
1 02 G N D -P 1 183 1 2 205
C_CX/2
87, 89
C_CW/2
/2 . B 6 86
1
flasher
94
78
77
right rear
C_CX/2
C_CW/2
flasher
right front
-H7
-X 9 s plic e
C -X 1 3 s plic e C
7 6, 85, 86 81, 77
93, 94 9 5, 92
2
pow-X9 85
114 -X 1 4 s plic e
-H4
1
113 -X 1 1 s plic e 7 8, 88
light
1
position
C_DI/2
98, 99 79
C_BG/3
C_AR/3
2
100,97
/1.E3
83, 214, 215 80
3
rear light/
-H12
brake light
84, 102, 103, 112, 114, 117, 101
3
109 G N D -X 1 1 7 5, 80, 8 3, 106
/2 . B 6
2
1 11 -X 1 0 s plic e
1
-H200
1 12
-X200
C_BW/3
headlight
7 9, 104, 105 105 201 201
1
1
C_DI/2
1 07, 108, 113 188 2 02 206
-H11
C_AZ/4
C_BK/4
lamp
2
2
D 189 203
D
3
licence plate
106 204
4
2.4 2.3 2.2 2.1
fla L -X 2 00 1 00 , 1 89
/1 . D 2
2
103
fla R -X 2 00 9 5, 188
1
99 /1 . D 2
C_CX/2
C_CW/2
-X 2 0 1 s plic e
flasher
left front
205, 206, 207
-H6
-H9
84
82
91
92
97
107
110,109
111
108
2
117 203
90
91
90
89
73
74
75
74
1
1 8 2 4 7 5 6 3 9 207
C_CX/2
1
C_CW/2
2
flasher
116 2 1
clutch
switch
left rear
C _ A D /1 2
C_AT/2
C_AL/2
E 2 1 C _ A V /2 E
C _ B D /1 2 C _ A I /2
2 1
-S9
2 1 C _ C D /2
C L U -A 2 C _ A H /2 C _ B L /2
/2 . D 4 t
LO HI P . light L R
-V 1 M
-S 7 G -K 5 -M3 -S 5
be a m horn fla s he r s witc h fla s he r diode c ooling te mpe ra ture
re la y fa n s witc h
F F
P a ge : 3
ma in ha rne s s -
750 . 1 1. 07 5. 00 0
6 9 0 S upe rmoto 2 0 0 7 ins trume nts -ta c home te r 750 . 1 1. 076 . 0 00
3 P.
13-5
1 2 3 4 5 6 7 8

2007 LC4 690 Repair Manual

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2007 LC4 690 Repair Manual

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REPAIRMANUAL2007

KTM Group Partner

3 REMOVING AND REFITTING ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

12 PERIODIC MAINTENANCE SCHEDULE

3.206.045-E Repair Manual 690 LC4

„NOTE” POINTS OUT USEFUL TIPS.

Use only ORIGINAL KTM SPARE PARTS when replacing parts.

All design and assembly modification rights reserved.

C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

Item no. of repair manual Page Current text Correct text

Name mechanic/shop foreman Company/work shop

SPECIAL TOOLS – CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

FIG PART NO DESCRIPTION

SPECIAL TOOLS – ENGINE

FIG PART NO DESCRIPTION

DISASSEMBLING THE ENGINE 4

PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

SEPARATING THE CASE HALVES, REMOVING THE CRANKSHAFT AND

Left side of the engine

– Remove the gear sensor 3.

– Pull out the thermostat 5, discard the gasket.

Right side of the engine

– 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.

– Unscrew the temperature sensor 4 (A/F 19 mm) and spark plug 5

Moving the engine to TDC

NOTE: the mark on the camshaft retaining bracket is in the middle of

4 – Remove the camshaft retaining bracket 4.

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

– Loosen the cylinder head screws 2 (A/F 14 mm or AH 8 mm) in a

NOTE: always replace the cylinder head screws.

– Lift off the cylinder head.

3 – Remove the screw 4.

2 – Unscrew the nut (A/F 27) on the rotor.

– Remove the nut and lock washer.

– Screw special tool 584.29.009.000 3 onto the rotor.

3 – Remove the rotor and unscrew the special tool.

Removing the timing chain and timing chain pinion

5 – Lift off the guide rail.

– Pull the cable guide 5 out of the opening.

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

– Loosen the clutch screws in stages in a crosswise direction and

– Remove the pressure cap 8.

– Hold the outer clutch hub with special tool 750.29.081.000 9

NOTE: the stepped disk mounted underneath usually sticks to the

– Remove the stepped disk 3.

– Take the half disks 4 out of the groove.

6 – Remove the pressure piece 7 and the pushrod.

Removing the starter drive

Disassembling the shift mechanism

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

3 – Remove both oil pump covers 4.

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

– Lay the engine on its side.

– Lift the balancer shaft 1 out of the bearing.

– Lift the crankshaft 2 out of the bearing.

– Pull out the shift rail 4.

SERVICING INDIVIDUAL COMPONENTS 5

RIGHT CASE HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

CHECKING THE OIL PUMPS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

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