690 LC4 DUKE 2012 SPARE PARTS MANUAL: ENGINE ENGLISH ART.NO.: 3CM088530LEN

Transcription

1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM088530LEN ENGLISH

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3 INDEX DIAGNOSTIC TOOL CLUTCH COVER ENGINE CASE BALANCER SHAFT 3x 4x 5x 7x CYLINDER CRANKSHAFT, PISTON CLUTCH TRANSMISSION I - MAIN SHAFT 8x 9x 10x 11x TRANSMISSION II - COUNTERSHAFT SHIFTING MECHANISM WATER PUMP COOLING SYSTEM 12x 13x 15x 16x 1

4 INDEX VALVE DRIVE TIMING DRIVE CYLINDER HEAD LUBRICATING SYSTEM 17x 19x 20x 21x IGNITION SYSTEM ELECTRIC STARTER THROTTLE BODY 22x 23x 24x x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 2

5 DIAGNOSTIC TOOL DIAGNOSTIC TOOL HUSABERG/KTM DIAGNOSTIC TOOL KTM BREAKOUT-BOX KPL BREAKOUT-BOX TEMPLATE LC8 / RC TEMPLATE LC TEMPLATE HUSABERG ADAPTER LC4 EFI ADAPTER LC4 EPT/HUSABERG EFI ADAPTER LC DIAGNOSTIC HASP DONGLE XC POWERSUPPLY 220V/12V FOR AVL EXTENSION CABLE DIAGNOSTIC CABLE HUSABERG DIAGNOSTIC CABLE KTM CASE FOR DIAGNOSTIC-TOOL DIAGN. CABLE EXT. POWER SUPPLY DVD KTM XC-1 UPDATE V FRAME XC_1 SCANBOX KTM ADAPTER LC / C * NEW PART X AS REQUIRED 3

6 CLUTCH COVER CLUTCH COVER CPL PLUG CPL. M24X DOWEL 9,8 X 7 X OIL LEVEL GLASS CIRCLIP OIL LEVEL GLASS SHAFT SEAL RING 17X28X7B VITON CLUTCH CASE GASKET SCREW PLUG HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X35 TX O-RING 19,00X3,00 NBR / C * NEW PART X AS REQUIRED 4

7 ENGINE CASE ENGINE CASE CPL.W.BEAR. LC O-RING 6,00X1, PLUG DIN0910-M 10X COPPER GASKET DIN X14X DOWEL 6X8X11, OIL JET 50 M6X0,75 WS WASHER DIN9021-A 5, FLAT HEAD SCREW ISO 7380 M5X VENTILATION CONNECTOR M16X1, O-RING 17,17X1,78 GLO PLUG M20X1,5 WS= OILDRAIN PLUG W.MAG. M 12X1, HH COLLAR SCREW M6X35 TX CU-SEAL RING DIN X18X1, CASE BUSH AH SCREW DIN7984 M5X10 A COVER LOCK PIECE BUSHING PIN O-RING 18,00X2,00 NBR BUSHING PIN DOWEL 17 X 13 X DOWEL 21X MEMBRANE STOP SHEET MEMBRANE CYLIND.SCREW M3X8 ISO SS HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X70 TX CU-SEAL RING DIN7603-6X10X JET AH SCREW DIN0912-M 6X CLAMP STD DN HOSE BREATHER SYSTEM CABLE TIE 200/3,6MM BLACK / C * NEW PART X AS REQUIRED 5

8 ENGINE CASE SECURING GUIDE CHAIN GUARD SPECIAL SCREW M6X12,5 WS= HH COLLAR SCREW M6X80 TX GASKET SET LC / C * NEW PART X AS REQUIRED 6

9 BALANCER SHAFT BALANCING SHAFT COMPL THRUST WASHER DIN X32X,1 x THRUST WASHERDIN X32X,15 x THRUST WASHER DIN X32X,2 x THRUST WASHER DIN X32X,3 x BALL BEARING 62/22 C / C * NEW PART X AS REQUIRED 7

10 CYLINDER CYLINDER + PISTON D= HH COLLAR SCREW M6X25 TX CYLINDER BASE GASKET GROOVED PIN DIN1474 5X / C * NEW PART X AS REQUIRED 8

11 CRANKSHAFT, PISTON CRANKSHAFT CPL WOODRUFF KEY DIN6888 4X5X CYL.ROLLER BEARING NJ207 ECPC SHIM WASHER 36X48X0,10 x SHIM WASHER 36X48X0,15 x SHIM WASHER 36X48X0,20 STEEL x SHIM WASHER 36X48X0,30 x PRIMARY GEAR 36T NUT FOR PRIMARY GEAR DRIVE WHEEL BALANCER SHAFT TENSION PIN ISO X TIMING PULLEY WOODRUFF KEY DIN6888-3X5X WOODRUFF KEY 5X6,5 HARDED CIRCLIP DIN X1,5 NIRO LOCK WASHER VSK HEXAGON NUT DIN0936-M18X1,5 R SHAFT SEAL R.35X50X7B VITON CONNECTING ROD REPAIR KIT PISTON PIN CIRCLIP I PISTON I CPL. D=102 x II PISTON II CPL. D=102 x PISTON RING KIT CRANKSHAFT REP. KIT 690 x / C * NEW PART X AS REQUIRED 9

12 CLUTCH HH COLLAR SCREW M5X25 ISA SPRING RING CLUTCH SPRING 3,0X33, PRESSURE CAP HEXAGON NUT M20X1,5 7MM LOCK WASHER INNER CLUTCH HUB MOVABLE CLUTCH RELEASE SPRING INNER CLUTCH HUB FIXED STEPPED WASHER HALF-WASHER OUTER CLUTCH HUB CPL OIL PUMP DRIVE WHEEL NEEDLE BEARING K26X30X22ZW.KSE WASHER 26X40X GROOV.BALL BEAR RSR C PRESSURE BOLT PUSH ROD GASKET FOR SLAVE CYLINDER O-RING 30,00X1,50 NBR BLEEDER SCREW WITH CAP OUTPUT CYL. WITH BLEEDER SCREW HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X20 TX STEEL DISK 1,5 MM LC LINING DISK 2,7MM FCC RONDELLA ANTIVIBRAZIONE SET LINING DISC CUT OUT STEEL DISK 1,5MM NITRIDED HOLDING SCREW GMB-M5X CLUTCH KIT 690 LC / C * NEW PART X AS REQUIRED 10

13 TRANSMISSION I - MAIN SHAFT BALL BEARING 58/28 C4 N MAIN SHAFT NEEDLE BEAR. K 22X26X13 TN STOP DISK 22,7 X 32 X 1, CIRCLIP D IDLER GEAR 5.G /4TH GEAR MAINSHAFT IDLER 6. GEAR SOLID GEAR 2.G SHIM 20X32X BALL BEARING 6004 DDUN C GUIDE BUSHING BUSHING 25X28X WASHER DIN9021-A 5, FLAT HEAD SCREW ISO 7380 M5X / C * NEW PART X AS REQUIRED 11

14 TRANSMISSION II - COUNTERSHAFT COUNTER SHAFT SLIDING GEAR 6TH G CIRCLIP D STOP DISK 22,7 X 32 X 1, IDLER 2. GEAR NEEDLE BEAR. K 22X26X13 TN CYL.ROLLER BEARING NJ205 C SHAFT SEAL R. 32X47X7BSL VITON O-RING 25,12X1,78 NBR SPACER BUSHING 12MM ENGINE SPROCKET 15 T DAMPED x ENGINE SPROCKET 16 T DAMPED x ENGINE SPROCKET 17 T DAMPED x LOCK WASHER SPROCKET NUT LC BALL BEARING 6004 DDUN C SHIM 20X32X IDLER GEAR 1ST GEAR NEEDLE BEARING K22X26X13H STOP DISK 22,2X31,7X TH GEAR COUNTERSHAFT IDLER GEAR 3.G IDLER GEAR 4.G CIRCLIP DIN471 20X1, BUSHING 25X28X WASHER DIN9021-A 5, FLAT HEAD SCREW ISO 7380 M5X COUNTER SHAFT REP.KIT 690 x / C * NEW PART X AS REQUIRED 12

15 SHIFTING MECHANISM SHIFT FORK F. SLIDINGGEAR SHIFT FORK F. SLIDINGG. 3/ SHIFT FORK F. SLIDINGGEAR NEEDLE ROLLER DIN5402 6X14, SHIFTRAIL SHIFT SHAFT CPL TENSIONING SPRING 0,8MM SPRING GUIDE RETURN SPRING STOP DISK 14X30X1,5 STEEL NEEDLE BEAR.HK X20X SHAFT SEAL RING 14X24X6B VITON SHIFT LEVER CPL SHIFTING LEVER SPRING BOLT 6X25 FOR SHIFT LEVER STEEL WASHER 6,4X17X PAIR OF WASHERS M 6 NORDLOCK SPECIAL SCREW M6X16 WS= HH COLLAR SCREW M6X20 TX LOCKING LEVER CPL SLEEVE FOR LOCKING LEVER ARRESTING LEVER SPRING AH SCREW DIN0912-M 6X SHIFT DRUM LOCATING CPL BALL BEARING C SHIFTING DRUM CPL NEEDLE BEAR HK X42X CONTACT SPRING CONTACT BOLT SPACER SPRING FOR OPERATING SHAFT WASHER DIN0125-A 5, FLAT HEAD SCREW ISO 7380 M5X O-RING 25,30X2,40 NBR GEAR-POSITION SENSOR / C * NEW PART X AS REQUIRED 13

16 SHIFTING MECHANISM BRACKET F. GEAR-POS. SENSOR WASHER DIN0125-A 5, S CYLIND. SCR. DIN6912 M5X / C * NEW PART X AS REQUIRED 14

17 WATER PUMP THERMOSTAT SUPPORTING SLEEVE HH COLLAR SCREW M6X20 TX THERMOSTATCOVER HH COLLAR SCREW M6X30 TX WATERPUMP COVER WATER PUMP COVER GASKET HH COLLAR SCREW M6X15 TX WATER PUMP ROTOR FORM WASHER 16X1 NIRO SHAFT SEAL RING. 12X30X7 VITON SHAFT SEAL RING 12X30X7 PTFE GROOVED PIN DIN1474 5X / C * NEW PART X AS REQUIRED 15

18 COOLING SYSTEM RADIATOR VW HOSE 6X10 EPDM PLUG F. EXPANSION TANK YDNAC-CLAMP MM x HH COLLAR SCREW M5X12 TX HH COLLAR SCREW M6X10 TX O-RING 17X1,5 NB THERMOSWITCH LC8 102DG ' SPECIAL SCREW M6X21 WS= RUBBER SLEEVE D=12MM RADIATOR CAP 50 LC 1,0 BAR RADIATOR HOSE VARIABLE ONE-EAR CLAMP 32,5MM CLAMP STD DN FAN COWL RADIATOR HOSE FAN CPL. 12V LC EJOT PT SCREW K50X HH COLLAR SCREW M6X10 TX RUBBER GROMMET 20X15-M6X10 (1) SELF LOCK. NUT DIN0985-M ALU-GASKET 6X10X EXPANSION TANK CPL WASHER DIN0433-M12 A SCREW OIL TANK FIXING / C * NEW PART X AS REQUIRED 16

19 VALVE DRIVE INTAKE VALVE EXHAUST VALVE VALVE SPRING HOLDER VALVE-STEM SEALING RACING VALVE SPRING KIT VALVE SPRING RETAINER VALVE COLLET MK SHIM D=10/1,85 03 x SHIM D=10/1,90 03 x SHIM D=10/1,95 03 x SHIM D=10/2,00 03 x SHIM D=10/2,05 03 x SHIM D=10/2,10 03 x SHIM D=10/2,15 03 x SHIM D=10/2,20 03 x SHIM D=10/2,25 03 x SHIM D=10/2,30 03 x SHIM D=10/2,35 03 x SHIM D=10/2,40 03 x SHIM D=10/2,45 03 x SHIM D=10/2,50 03 x SHIM D=10/2,55 03 x SHIM D=10/2,60 03 x SHIM D=10/2,65 03 x SHIM D=10/2,70 03 x SHIM D=10/2,75 03 x SHIM D=10/2,80 03 x SHIM D=10/2,85 03 x SHIM D=10/2,90 03 x SHIM D=10/2,95 03 x SHIM D=10/3,00 03 x SHIM D=10/3,05 03 x SHIM D=10/3,10 03 x SHIM D=10/3,15 03 x SHIM D=10/3,20 03 x / C * NEW PART X AS REQUIRED 17

20 VALVE DRIVE ROCKER ARM EXHAUST CPL ROCKER ARM INTAKE CPL ROCKER ARM SHAFT AH SCREW DIN912 M6x AH SCREW DIN0912 M 6X VALVE KIT 690 LC x / C * NEW PART X AS REQUIRED 18

21 TIMING DRIVE NEEDLE SLEEVE HK1814RS18/24/ NEEDLE SLEEVE HK4012B40X47X CAMSHAFT CAMSHAFT HOLDER HH COLLAR SCREW M6X12 TX AUTO DECOMPRESSION HALF MOON RING H6-BLS AUTO DECO WEIGHT SPRING FOR AUTO DECOMPR DECO SCREW TIMING CHAIN HOLDING BOLT O-RING 10,00X1,00 NBR 70 SH SCREW PLUG CHAIN ADJ CU SEAL-RING 20X27X CHAIN ADJUSTER HYD TENSIONER RAIL SECURING GUIDE GUIDE RAIL SUPPORTING SLEEVE S HH COLLAR SCREW M6X30 TX TIMING PINION CIRCLIP DIN X1,5 NIRO O-RING 18,00X2,00 NBR / C * NEW PART X AS REQUIRED 19

22 CYLINDER HEAD CYLINDER HEAD CPL CYLINDER HEAD GASKET GROOVED PIN DIN1474 5X STUD DIN0835-M 8X VALVE GIUDE EXHAUST VALVE GIUDE INTAKE SHIM 10,2X19X1,5MM CYLINDERHEAD SCREW M10X168WS TEMPERATURE SENSOR WATER O-RING 10,00X2,00 SILCONE SCREW PLUG SEALING PLUG VALVE COVER GASKET VALVE COVER BREATHER COVER COLLAR SCREW M5X12 ISA O-RING 15,00X1,50 VITON VALVE COVER SCREW DECOUPLING ELEMENT INTAKE BOOT HOSE CLAMP GEMI 70MM CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M6X8 TX HH COLLAR SCREW M6X25 TX ENGINE BREATHER HOSE CYL.HEAD CLAMP STD DN CLAMP 21X12 STD-DES / C * NEW PART X AS REQUIRED 20

23 LUBRICATING SYSTEM TAB WASHER DIN6799-RS 6, STOP DISK 8,1 X 15 X 0, OIL PUMP GEAR 20-T S AH SCREW DIN7984 M5X10 A OIL PUMP SHAFT NEEDLEROL.DIN5402 NRA 2,5X19, NEEDLE ROLLER DIN5402 2,5X11, OIL PUMP ROTOR COMPL. 15MM OIL PUMP ROTOR COMPL. 10MM HH COLLAR SCREW M5X16 TX OILFILTER CAP O-RING 39,34X2, OILFILTER COVER OIL PIPE OIL FILTER SHORT OIL FILTER LONG VALVE PISTON D=10MM OIL PRES.SPRING 5 BAR RED CU-SEAL RING DIN X18X1, PLUG DIN0908-M12X1, O-RING 12,5X1,5 VITON V OIL SCREEN O-RING 17,17X1,78 GLO PLUG M20X1,5 WS= OIL PUMP COVER OIL PUMP SHAFT OIL PUMP DRIVE WHEEL OIL PUMP COVER S INT. TORX FLAT HEAD M5X S HH COLLAR SCREW M6X16 ISA OIL PRESSURE SWITCH "BITRON" COPPER GASKET DIN X14X / C * NEW PART X AS REQUIRED 21

24 IGNITION SYSTEM IGNITION COVER DOWEL 9,8 X 7 X CABLE SUPPORT GENERATOR O-RING 24X2,5 VITON SCREW PLUG M24X1,5 PA IGNITI.COVER GASKET STATOR INSET ROTOR HH COLLAR SCREW M6X16 TX STICK COIL HOLDER STICK COIL O-RING 18,00X2,00 NBR SPARK PLUG M12X1,25 "8" HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X30 TX PULSER COIL SPECIAL SCREW M6X16 WS= SPARK PLUG NGK "LMAR7A-9" / C * NEW PART X AS REQUIRED 22

25 ELECTRIC STARTER E-STARTER ENGINE CPL O-RING 33,5X3 VITON HH COLLAR SCREW M6X20 TX NEEDLE SLEEVE HK X23X STARTER INTERMEDIATE GEAR NEEDLE BEARING K17X21X FREE WHEEL TORQUE LIMITER STOP DISK 17,2X25X CIRCLIP DIN X CIRCLIP DIN0472 J FREE WHEEL GEAR HH COLLAR SCREW M 6X NEEDLE BEAR. K 26X30X STOP DISK 17,2X22X CIRCLIP DIN X / C * NEW PART X AS REQUIRED 23

26 THROTTLE BODY THROTTLE BODY MAP SENSOR CPL FUEL RAIL ASSY SET FUEL INJECTOR ASSY SET SCREW TORX M5X PRESSURE SENSOR HOLDER RANGE CHANGE METAL NUT M O-RING PLATE, STAY SCREW WASHER O-RING SCREW SHOULDER SCREW SHOULDER SEAL RING RUBBER SUPP. PRESSURE SENS PRESSURE SENSOR HOSE 3,2X8,5 PER METER x ROLLOVER SENSOR SHIM 4,3X15X1,25MM GALVANIZED AH SCREW DIN0912-M 4X AMBIENT-AIR TEMPERATURE SENSOR INT. TORX OVAL HEAD M5X RUBBER CABLE TIE 60MM TIMING CHARGER EFI AMBIENT-AIR TEMP. SENSOR CABLE HH COLLAR SCREW M6X10 TX TIMING CHARGER EFI HOLDER / C * NEW PART X AS REQUIRED 24

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28 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM088530LEN* 3CM088530LEN Art.Nr.: 3CM088530LEN 11/2011