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Old 10-11-2014, 08:53 AM   #1
LethPhaos OP
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KTM 690 SMC engine rebuild



A while ago it turned out my primary gear shaft bearing on the clutch side was failing. This came at a bad time, so I ignored it for a while to ride the HAT first. The bike made it, winter is coming, so time for the rebuild.

This is after only a couple 100 km (HAT + one day ride) on fresh oil...


I've never done anything like this before, so this is going to be interesting. There are not that many 690 rebuild threads around to learn from so I'm hoping to get some feedback from you guys to help me along

So far I've removed the engine from the frame, nothing mayor, went easily enough.


Throttle body is rather dirty, I'll have to clean that up. I'm thinking I might have beein using too much oil on the filter. I don't trust the air box either, it seems to leak a bit on the bottom where the air temp sensor sits and between the rubber/plastic tube that connects to the throttle body.


My engine holding frame, it will help me keep the block steady while I work on it.


Everything disconnected, ready to remove the engine. I prodded the frame up with axle stands and supported the rear wheel to take pressure of the swingarm axle. I used a cross lift to lower the engine a bit, then took it out by hand.




Naked bike!


Ready for cleaning


Off course it started raining while I was out cleaning the block. Less work for me right

That's it for today, ready to start on the real work next time.
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Old 10-11-2014, 09:02 AM   #2
Pa_Lethphaos
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Good luck!
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Old 10-11-2014, 09:38 AM   #3
larryboy
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Quote:
Originally Posted by LethPhaos View Post
Throttle body is rather dirty, I'll have to clean that up. I'm thinking I might have beein using too much oil on the filter. I don't trust the air box either, it seems to leak a bit on the bottom where the air temp sensor sits and between the rubber/plastic tube that connects to the throttle body.

I'm thinking it's been sucking dirt instead of air, valves/seats/piston/bore are probably shot.
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Old 10-11-2014, 09:38 AM   #4
JustBob
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Thumb

Thanks for documenting this. I usually don't keep a bike long enough to need a rebuild but I may this one and it's always interesting to see how it's done.
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Old 10-11-2014, 09:55 AM   #5
Schussboelie
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I'm in!
I won't be of much help but I'm looking forward to your progress.
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Old 10-11-2014, 10:49 AM   #6
gunnerbuck
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I'll follow
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Old 10-11-2014, 10:51 AM   #7
thumpididump
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Old 10-11-2014, 02:48 PM   #8
mrwwwhite
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I'm in. Just finished rebuilding my 690 also (frame fracture) and plan to make a new thread with it.
Good luck with the rebuild.
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Old 10-11-2014, 02:50 PM   #9
hahmule
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lurking & learning
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Old 10-11-2014, 07:40 PM   #10
slidefighter
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This is way cool and should be helpful to all serious 690 riders. I'm in..


Lee...
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Old 10-11-2014, 08:19 PM   #11
sprouty115
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Originally Posted by slidefighter View Post
this is way cool and should be helpful to all serious 690 riders. I'm in..


Lee...
+1...
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Old 10-11-2014, 10:44 PM   #12
MeinMotorrad
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In.
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Old 10-14-2014, 01:14 PM   #13
LethPhaos OP
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welcome all, glad to have you along :)
not a very productive session today, but any progress is better than none

spent most of my time fabbing an engine holding screw, could have been done much faster but I shortened my only M8 bolt too much rendering it useless. ended up using a piece of threaded rod instead. painted it orange, so now it's better than the KTM approved tool



with engine in TDC I started removing the external parts. done so far: oil filters, starter motor, gear sensor, alternator cover, valve cover







I don't like that rusty looking stuff, the picture makes it pop out more than it does to the naked eye though. humid workshop :(

and here's my first question: how do you remove the countershaft spacer without damaging it? I didn't try any tools, but it seems on too tight to be removed by hand
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Old 10-14-2014, 02:54 PM   #14
gunnerbuck
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Quote:
Originally Posted by LethPhaos View Post


I don't like that rusty looking stuff, the picture makes it pop out more than it does to the naked eye though. humid workshop :(

and here's my first question: how do you remove the countershaft spacer without damaging it? I didn't try any tools, but it seems on too tight to be removed by hand
The countershaft bushing is something that can usually be pulled out by hand, if not gently grip it with pliers and pull it out.. The sealing parts of the bushing are inside the case and not easily damaged...
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Old 10-15-2014, 07:08 AM   #15
LethPhaos OP
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thanks, I'll look at that next time.
just ordered a flywheel puller, could take 20 days to arrive... this project is going to take a while
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