NHTSA ID Number: 10180161
Manufacturer Communication Number: TB1814
TSB/Document Date: 2020-09-30
Summary
During the course of quality controls, KTM
North America, Inc. has found that the tolerances between the decompression weight and decompression screw (marked in blue) are not in specification on select 2018 690 Duke model motorcycles. These auto-decompression system components must be replaced to prevent premature wear.
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
REPLACEMENT OF AUTO-DECOMPRESSION
SYSTEM COMPONENTS
AFFECTED MODELS: 2018 KTM 690 DUKE
RESTRICTIONS: AFFECTED MODELS ARE LINKED BY VIN IN KTM
DEALER.NET
KTM North America, Inc. is recommending that the auto-decompression system components are
replaced on all affected 2018 690 Duke motorcycles including the current inventory prior to PDI
following the procedures given later in this document. Please contact all of your customers who own
affected motorcycles to have the auto-decompression system components replaced as soon as
possible.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
1
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
INITIAL INFORMATION:
During the course of quality controls, KTM North America, Inc. has found that the tolerances between
the decompression weight and decompression screw (marked in blue) are not in specification on
select 2018 690 Duke model motorcycles. These auto-decompression system components must be
replaced to prevent premature wear.
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
PROCEDURE FOR REPAIR:
You do not need to remove the engine to perform this repair. The following photos are for
reference only.
Please reference the latest HTML repair manual in the KTM Dealer.net download center, or on the
CD-Rom (p.n. 3.206.324) for additional instructions and tightening torques.
1.
2.
3.
4.
Remove the passenger and rider seat.
Remove the fuel tank.
Place the hoses and cables to one side.
Remove the valve cover (the valve cover seal can be reused if not damaged).
Note: Cover the timing chain tunnel opening to prevent parts from falling inside the engine.
5. Remove the screw (1) with the O-ring in order to rotate the engine to ignition top dead center.
Cover this area
with a clean shop
towel to prevent
parts from falling
inside the engine.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
2
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
6. Rotate the crankshaft counterclockwise until the balancer shaft (2) and camshaft (3) markings
align with the arrow markings of the camshaft bearing support.
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
7. Loosen the auto-decompression screws (4) (Torx 25) by two turns and detach springs (5) on the
auto-decompression weight (6).
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
Note: The adjusting screws (Allen Head socket) must not be loosened.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
3
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
8. Remove the screws, weights and springs from the camshaft. Take a photo of the parts removed
and attach them to the warranty claim that will be submitted for the repair.
9. Thoroughly degrease and clean the screw threads to ensure proper adhesion with the new
precoated screws (7).
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
10. Position the spring (5) and the (new) weight (6).
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
4
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
11. Position the (new) screw and turn in 5-6 rotations.
12. Install the spring (5) on the weight and ensure correct installation position.
13. Repeat steps 10, 11 and 12 with the other weight, spring and screw.
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
Note: The spring must not become trapped (See the blue arrows).
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
5
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
14. Tighten the auto-decompression screws (4) (Torx 25) to 4 Nm.
15. Check the following points:
• Spring is correctly fitted and positioned
• Weight is correctly positioned
• Check freedom of movement by hand
16. Clean the sealing areas.
17. Check the valve cover seal for any damage and replace if necessary.
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
Note: Check and verify correct position of ventilation flange gasket (8).
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
6
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
18. Mount the screw (1) with the O-ring and tighten (8 Nm).
19. The remaining components are installed in reverse order according to the repair manual.
20. Start the engine and check to be sure there are no oil leaks and the auto-decompression allows
easy starting after replacement.
Component
Auto-decompression screw
Screw, valve mechanism cover
Screw in ignition cover
Screw
Tightening
Torque
Remark
M4x0.5
4 Nm
Precoated with Loctite
M6
10 Nm
M24x1.5
8 Nm
PARTS ORDERING:
1 QTY. 76636015044 (Decompression weight repair kit)
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
7
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
TORQUE SPECIFICATIONS:
TB1814 KTM TECHNICAL BULLETIN - USA
JUNE 21, 2018
WARRANTY INPUT INFORMATION:
This Technical Bulletin only affects certain VIN numbers! Please check the VIN by performing a
Motorcycle History search in KTM Dealer.net to determine if it’s affected. If the motorcycle is
affected you will see a link to the bulletin and its repair status in the history results. KTM North
America will not warranty units whose VIN numbers are not linked as this bulletin does not
apply to them. It is the responsibility of the dealer to determine if the unit requires this update
by checking the vehicle history and understanding the instructions provided by this bulletin.
Please note that when entering a warranty claim on an affected model, you must perform a vehicle
history search, expand the Technical information window and click the orange arrow on the right
side of the corresponding bulletin message.
You can now choose the TI Number from the list. The TI number for this procedure is according to the
repairs performed and listed in the warranty claim input information; click Continue with selected
action code.
The Warranty Claim is automatically entered for you, including parts & labor. You must enter
additional information in the required fields marked with an asterisk “*” before submitting the claim to
KTM. The flat rate time for this repair is based on the action performed and provided in minutes.
WARRANTY CLAIM INPUT INFORMATION
TI Warranty
Subassembly group:
36 – Timing Drive
Failure code:
420 – Wearing
Part causing failure:
76636010244 – Camshaft, complete
Campaign code:
36_776610_00 Replacement of auto-decompression system
components
Spare parts:
1 QTY. 76636015044 – Decompression weight repair kit
Labor time:
50 minutes
Stock parts affected:
No
DEALER SERVICES DEPARTMENT © 2018 KTM North America, Inc. – All rights reserved
Warranty type:
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
8
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TSB/Document ID: TB1814
Replacement Service Bulletin Number:
MFR Communication Date: 2018-06-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:HARD PARTS INTERNAL/MECHANICAL
MFR Component System:
MFR Component Subsystem:
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