2007 KTM 690 LC4 Engine Repair Manual Printed

Description

This 92 page, printed 2007 KTM 690 LC4 Engine Repair Manual is an authorized KTM reproduction of the original out of print manual. This manual covers engine service for 2007 KTM 690 LC4 powered motorcycles. If you need information for your chassis or suspension please refer to the owners manual or suspension manuals for your forks and shocks.

Table of Contents
General Information
Special Tools – Chassis
Special Tools – Engine

Disassembling the Engine
Preparatory Work
Left Side of the Engine
Right Side of the Engine
Moving the Engine to TDC
Removing the Cylinder Head and Piston
Removing the Rotor
Removing the Timing Chain and Timing Chain Pinion
Removing the Clutch and Primary Pinion
Removing the Starter Drive
Disassembling the Shift Mechanism
Removing the Oil Pumps
Separating the Case Halves, Removing the Crankshaft and Transmission Shafts

Servicing Individual Components
Right Case Half
Left Case Half
Clutch Cover
Crankshaft Bearing
Drive Wheel on the Balancer Shaft
Measuring the Axial Clearance of the Crankshaft
Cylinder – Nikasil Coating
Measuring the Piston and Cylinder, Establishing the Mounting Clearance of the Piston
Piston
Checking the Piston Ring End Gap
Checking the Oil Pumps for Wear
Lubrication System
Automatic Decompressor
Timing Chain Tensioner
Timing Train
Cylinder Head
Shift Mechanism
Pre-Mounting the Shift Shaft
Clutch
Checking the Clutch
General Information on Servicing the Transmission
Assembling the Main Shaft
Assembling the Countershaft
Starter Drive
Checking the Freewheel
Replacing the Freewheel

Assembling the Engine
Mounting the Transmission Shafts, Assembling the Engine Case
Mounting the Oil Pumps
Mounting the Shift Mechanism
Mounting the Starter Drive
Mounting the Clutch and Primary Pinion
Mounting the Timing Chain Pinion and the Timing Chain
Mounting the Rotors
Mounting the Piston, Cylinder and Cylinder Head
Moving the Engine to TDC
Mounting the Camshaft
Mounting the Chain Tensioner
Right Side of the Engine
Left Side of the Engine

Troubleshooting

Technical Specifications
690 LC4 Supermoto / Supermoto Prestige
Engine
Chassis
Tightening Torques
Engine
Chassis
Tolerances, Mounting Clearances

Periodic Maintenance Schedule – KTM 690 LC4

Wiring Diagrams
690 LC4 Supermoto
Explanation of Connectors, Cable Colors
Start/Charging/Alarm System
EFI
Lights, Instruments, Flasher, Horn, Cooling Fan