Ktm 690 ...rocker arm issue or something else?

Discussion in 'Thumpers' started by lowslow, Apr 14, 2018.

  1. lowslow

    lowslow n00b

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    2013 ktm 690 refused to start (starter couldn’t turn engine to/past TDC) so I’ve spent the evening in the garage....

    Electricals are fine & so I suspected the autodecompression. The autodecompresion itself mechanism wasn’t seized, but in measuring valve clearances, both valves on the exhaust side are at about 0.8mm (yes, 0.8, not 0.08). I think with the exhaust valves that far out of spec, the autodecompressor cant actuate them.

    After searching on here it seems that rocker arms/bearings fail on these bikes & I’m guessing that’s what I’m looking at....

    Question is - how do I check if it’s the rocker arm/bearing that’s shot, and not something else? Should there be some free play somewhere that I can look at to diagnose?

    Thanks in advance!
    #1
  2. renogeorge

    renogeorge Let's ride!!

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    I would look for slop at the roller and movement of the roller pin. Many of the failures seemed to involve the pin walking out and jamming the adjacent rocker. Others were roller bearing failures. What is the casting mark on your rockers? The 2 digit code has been interpreted as a production/casting year for the rocker. 15 and later seem to have eliminated the problem. I changed the ones on my 2012 at 10k miles, even though no problems noted. $130 US. Good luck.
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  3. lowslow

    lowslow n00b

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    Well another look and feel has shown that the bearing on the right side of the arm has quite a bit of slop/play in the up-down direction.

    Will pull the arm off later and have a better look, but I think that the culprit is identified and I’m in for a new rocker arm. Should I do both intake and exhaust at the same time even though intake looks ok? At 15,000kms or so now...

    Should I replace the shafts as well or anything else, while I’m at it?
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  4. renogeorge

    renogeorge Let's ride!!

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    I doubt the shafts are damaged if the problem is on the roller end of the rocker. But check for scoring. I would definitely replace both rockers. Hopefully the new rockers will have the 15 or later/higher casting marks.
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  5. lowslow

    lowslow n00b

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    Thanks for the reply. The shafts turned out OK, but the bearing is certainly shot.

    I made a video for future readers.

    New intake and exhaust rocker arms on order...
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  6. sprouty115

    sprouty115 Long timer

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    Thanks for the update and the video. It's a well documented problem, but it's still good to let the community know about it. Knowing the casting marks would be helpful too.

    I would only add to renogeorge's advice that you should change the oil, clean the screens and replace the disposable filters. The rollers inside the bearing have been destroyed and the particles had to go somewhere.
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  7. lowslow

    lowslow n00b

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    The oil and filter change is a good idea!

    Here’s a photo of the casting marks ...09 apparently - some new-old-stock perhaps?!

    Attached Files:

    #7
  8. sprouty115

    sprouty115 Long timer

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    Is that what came out of the bike, or what you just ordered?

    Assuming that was what was in there, then, yes those were N.O.S. or possibly used rockers someone installed. You can tell by the "x" markings on each end of the bearing axle.
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  9. lowslow

    lowslow n00b

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    Yep, that’s what came out of the bike.

    The intake rocker had a “12” on it... the bike’s service history doesn’t mention new rockers and I’ve had it since 5,000km, so a bit unlikely that it’s had a precious failure - go figure!
    #9
  10. sprouty115

    sprouty115 Long timer

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    Well on the plus-side you caught it before it grenaded your engine and new rockers will solve the problem for good.
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  11. AJRJ

    AJRJ Adventurer

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    Hi guys. I'm watching this closely, as I build up a low mile (4,500) 2012 while I wait for the snow to melt.

    I'm curious to see that you get the newer casting numbers when you receive your order. Are they still shipping old numbers? I was going to just run mine, as they seemed to be fine during a valve adjustment, but I'm learning 2012 is definitely a year that will need the updates.
    #11
  12. sprouty115

    sprouty115 Long timer

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    If you are in the US and order from a reputable place like Slavens or Munn Racing you will get the latest rockers - what I was told when I ordered mine was they don't stock them, rather they get them directly from KTM, which only has new product.
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  13. AJRJ

    AJRJ Adventurer

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    Thanks. I'm in Canada, but the local dealer here in Calgary is pretty good.
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  14. sprouty115

    sprouty115 Long timer

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    You should be fine then. I really don't think you'll find anymore N.O.S.
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  15. kennyh

    kennyh Been here awhile

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    A21212F7-7D61-4E5B-9867-68E17FF9BDB6.jpeg
    Looks familiar. Same symptoms too. New rocker time for sure
    #15