KTM 690 Manual Cam Chain Tensioner Install

[@JohnHowerton137]

* Place the engine at Top Dead Center before installing the tensioner. You can rotate the engine by placing the transmission in a high gear and rotating the rear wheel while on a stand.

[@Tdmotoss]

Yeah, OK, and how are you supposed to know it's at TDC, when you do not have the valve cover off the engine ......

[@JohnHowerton137]

@@Tdmotoss Then take the time to take the cover off and line up the TDC mark on the cam 🤷🏼‍♂️

[@JohnHowerton137]

This video was recorded Jan 28th 2021. So far the part has worked flawlessly outside of a few drips of oil. I checked the adjustment once since then (Aug/21) after a few thousand miles of riding. Still happy with the part and function.

[@dasatom3060]

Hey, what you said in the End that the engine runs smoother can be true. Because when the chain was not so tight with the old tensioner the timings may not be perfect, because of the play. So the valves didn‘t open/close to the 100% correct time. Now with the manual one, you tightened the chain much stronger. So the timings now are 100% correct, therefore your bike feels smoother. 👋🏻

[@Ohvurr_leveraged]

It does make a noticeable difference in power because it is working more efficiently.

[@JohnHowerton137]

My seat of the pants says its at least a smoother delivery.

[@alfredoscardino7028]

Ciao! Thank you for the great tutorial! Just a question, where is the rubber O-ring? It can be removed from the inside? Thanks🎉

[@stugoon]

Just bought a used 2020 701 that does sound noisy. i'll have a look at this, nice one, thanks for sharing.

[@monkcox1662]

I bought a dirt tricks tensioner that is auto matic . I have not put it in yet

[@1888ducati]

Thank you John for the video. How do you when its TDC?

[@JohnHowerton137]

I believe there's videos on YT to check that. I just removed stock one and slid the new one right back in on both my bikes and adjusted it up before ever running. No reason the chain should jump doing that with an engine that was never turned over. This is not advice, do what the manual says... it's just what I did.

[@firstamendmenttshirt4768]

The engine sounded smoother when you hit the throttle like rolling on.

[@JohnHowerton137]

I do feel like it runs smoother. I just have no way to prove it. And it’s far more noticeable on the road than just running on the stand.

[@firstamendmenttshirt4768]

@@JohnHowerton137 1, 2, 3 might act different.

[@JohnHowerton137]

@@firstamendmenttshirt4768 1,2,3 what?

[@firstamendmenttshirt4768]

@@JohnHowerton137 mode 1 2 3

[@JohnHowerton137]

@@firstamendmenttshirt4768 what’s that have to do with the cam chain tensioner? I only run the advanced map. Power to weight ratio on this bike is lower than I’m use to... outside of maybe the 250F.

[@watsyt5]

Hi John,good video,im going to fit a manual tensioner to my 21 690,i seen you fitted tensioner without setting at TDC,ive read on other sites it needs to be at TDC but dont want to remove everything to remove rocker cover is there another way of checking engines at TDC before fitting any info welcome.Thanks

[@Tdmotoss]

No, there isn't as far as I know.

[@JohnHowerton137]

Been so long and I have 8 bikes, I feel like there is a screw or cap in near near the front of the crankcase that you can see a mark through. Sorry I don't have time to look it up now, barely slept in days I've been so busy. I may have posted it somewhere in this comment section in the past.

[@SEMCINTYRE1]

Also, you mention that this didn’t help the engine noise but your video in the beginning sounds like it did. Are you still experiencing this noise? Also, can this part be replaced with stock part?

[@JohnHowerton137]

They’re just noisy engines in general. I expected it to make a lot less noise, but there is just a lot of piston slap sound in that big old milk jug 😆 If you have an aluminum skid plate on your bike, take that off and ride around for a while. They resonate sound like crazy! I finally lined mine with some foam matting stuff. If I know I’m going to ride nothing but street I put my stock one back on, but I’ve kind of stopped doing that, because then you can’t lift it on a stand. There isn’t really enough flat surface. I obviously don’t know if the sounds you’re hearing are normal or not, but they are noisy engines. Most if not all big singles are.

[@Serveronmc]

Maby a dumb question, but do you need to emty your bike for oil to do this? Just did an oilchange and godt a problem where the oil lamp starts blinking at idle. There is also some noise when this hapens. Seen some people recomed to to this. Thanks !

[@JohnHowerton137]

Is your oil level in the middle of the sight glass? If not, it can flicker. No, this does not require the bike empty.

[@trevormassey7313]

Hey man, I'm having the exact same issue right now. Did you end up replacing the timing chain tensioner? And did it fix it?

[@Ohvurr_leveraged]

Thanks for making this!

[@SEMCINTYRE1]

I’m having this same noise that’s been concerning me. I have a 2018 also. It’s a click/rattle and it seems to be intermittent and I comes in when riding with throttle at 3k rpm-sh. Goes away when I let off gas. Don’t really hear it at idle. Any thoughts? Appreciate the videos btw!

[@JohnHowerton137]

Usually the noise would the opposite of that. The auto style tensioners build tension on the chain as the RPMs/Oil pressure increase. They’re pretty noisy engines in general, you might just be hearing piston noise. When it doubt take it to the dealer.

[@SEMCINTYRE1]

I think you’re probably right and I’m just being paranoid. It’s fairly faint, but noticeable and definitely a tick/rattle sound. I called the dealer and they said the same thing. They’re gonna take a listen for me. It’s only got 4400 miles on it.

[@JohnHowerton137]

Hope it worked out. Sorry, this KZbin creator studio comment system is complete dogchit. I wish it worked like the normal KZbin app does, but for some reason it doesn’t and loads of comments go unseen. It also doesn’t @ the commentor that’s being responded to 🤦‍♂️

[@SEMCINTYRE1]

@@JohnHowerton137 The dealer took it out and confirmed I am just being paranoid. Normal loud engine noises.

[@SEMCINTYRE1]

@@JohnHowerton137Which was great news, bc I’ve had a number of random issues in my first season with it. Gear position sensor issue, a loose relay I didn’t notice had me stranded, gear shifter came loose about fell off, kick stand sensor. I was getting frustrated. The engine would have been the straw.

[@guyhockeyguy]

Thanks. I've been waiting to do this as well. Where is the part purchased from?

[@JohnHowerton137]

I believe this was Ebay. Likely China. Nobody else had any inventory when I was looking (or they resold the same China one for 2x the price. *cough* UK sites). Machining on the bolt isn't the cleanest ever, but it's worked fine for the past 9 months.

[@JohnHowerton137]

Yeah, it was. Found the link: www.ebay.com/itm/Manual-Cam-Chain-Tensioner-For-KTM-690-SMC-R-DUKE-Enduro-SUPERMOTO-SMC-DUKE-R-/273376954283?mkcid=16&mkevt=1&_trksid=p2349624.m46890.l6249&mkrid=711-127632-2357-0

[@ritchfrancis7553]

I just bought the same CCT. How do you determine the baseline adjustment? Did you initially measure and set the length the same as the previous one and fine tune it according to the engine sound?

[@JohnHowerton137]

Just screwed it in until it stopped then turned it in a little. 1.5 turns or something? On my 250F I roughly adjusted the new one the same length, then followed that same thing as above. Both bikes have be running perfectly. I checked/re-set just for the sake of doing it on the 690 after a 1,000 miles or something. I feel like is makes the bike feel way better off the bottom. Roll on things just feel more efficient down there. If you haven't already, take the stock filer out and do the airbox too. Bike feels soooo much better. i've been using my stock filter while my phone has been on backorder for the last two months. Just got the foam back in and it was instant smiles 🥰

[@hanzo52]

Is there any kind of sealant to put on the threads of the cct? The oil seeps out in the threads

[@JohnHowerton137]

I'm sure something like that could be done. Mine wasn't a problem after the first 1,000 miles.

[@hanzo52]

@@JohnHowerton137So oil-free for 1000 miles and then leak?

[@JohnHowerton137]

@@hanzo52 opposite.

[@hanzo52]

@@JohnHowerton137 Leaked dry for 1000 miles and then no more oil to leak?

[@JohnHowerton137]

@@hanzo52 dribbled some residue for a while and hasn't been noticeable since. I'm not looking for it, but also not noticing anything.

[@sAu54g3]

Hey john. Been reading through comments, seems like you know your stuff! You know if the older LC4 engine has the option to run a manual tensioner as this one? Have noticed my engine e getting slight noisier, was thinking good place to start

[@JohnHowerton137]

This should be the one for the older engine. www.ebay.co.uk/itm/323224409886 Just double check, as I have no idea what you have. Before you start throwing a bunch of money at parts, I’d verify that your valves are adjusted correctly and do a leakdown test to see if it’s just tired. If you recently added a skid plate, they also dramatically increase engine noise.

[@sAu54g3]

@@JohnHowerton137 thanks john 👍

[@TheSpragz]

What year bike is this? Would this be possible on my 2021?

[@JohnHowerton137]

This is a ‘18, but yes, as long as order the part for the 2021.

[@TheSpragz]

@@JohnHowerton137 cheers. I have a timing chain rattle for the first few seconds after starting when warm. It goes away once the oil has reached tensioner. Not sure if it’s normal.

[@JohnHowerton137]

@@TheSpragz it's normal, but I don't like it either. They do fail sometimes. The KTM group race teams all replace them with Manual tensioners. Auto stuff is only for the general public. Less maint/adjustments.

[@riccicrozzie8204]

Mate, I don't know who taught you how to wrench, but please take a few classes , there's the right way,and your way. Cam chain tension is not hit and miss, the extra tension you applied while the motor was running was not a good idea. There's a reason specifications and procedures exist. Please don't ever adjust your valve lash.

[@JohnHowerton137]

Noted. This 4T stuff is not my wheelhouse, this seemed like common practice and even some instructions. I’m all about the correct way, can you point me to video/page you think does it right?

[@riccicrozzie8204]

@@JohnHowerton137 , John, I apologize for sounding like an ass, , this may help . Nihilo KTM / Husqvarna Manual Cam Chain Tensioner Instructions *** Motor Must be @ TDC *** Remove Stock tensioner from the motor with a 24mm wrench. Retain the brass crush washer for use with the Nihilo tensioner Remove the blue locking nut from the tensioner and screw the SS pusher assembly all the way into the black insert until it bottoms out Install the brass crush washer onto the black insert and slide the assembly into the motor and start threading it in by hand finish by tightening with 19mm wrench With a 6mm wrench now turn the Stainless Steel threaded pusher clockwise (tighten) until you feel it touching the cam chain guide then tighten ½ turn to achieve the correct tension, next install the blue( your lock nut is silver)lock nut. While holding the 6mm head of the SS pusher stationary tighten the blue locking nut with a 13mm wrench You are done installing your new Nihilo Concepts manual Cam Tensioner. We suggest you check the tightness when servicing you motorcycle approximately every 6-8 hours. **Position motor @ TDC ** Simply remove the blue( silver) nut, back off the tensioner until it stops and then re-tighten by hand until you feel tension then go ½ turn more with the 6mm wrench and install the blue lock nut as described above. On new motors there will be very little free play , this insures that the chain cannot jump as the motor breaks in small adjustment may be necessary.

[@JohnHowerton137]

Are you going to post something to help the community, or just be a troll who knows the some "right way" and pretend this was somehow my way? I didn't check for TDC so I could see criticism there, but Nihilo Concepts (Factory KTM race team supplier) doesn't even do this. It's not uncommon practice to adjust while running. Since the access here is so poor, I wanted to make sure the adjuster hadn't hit a false finger tight stop before I added my 1/2 turn tension. I slowly adjusted in until I felt a few seconds of vibration (not even a whir sound) and backed it all the way back to the 1/2 turn setting, adjusting slowly in until it felt the smoothest and quietest, all while at idle. It's been running and popping off the rev limiter for thousands of miles flawlessly. I've rechecked it once. Your comment is starting to feel like the people who flame me for not pre-oiling my oil filters enough on a warm wet engine, then criticize me for changing my oil too often 🤣 Like it matters that it takes an extra 2.5 seconds at idle to saturate the oil filter, but it's cool to run wet clutch contaminated, fuel thinned Walmart diesel oil in a high performance 4T engine for thousands of miles and blame the mfg for soft cams or something when their top ends are smoked🤦‍♂️ So teach us something or shut up.

[@riccicrozzie8204]

@@JohnHowerton137 Okay 👍

[@JohnHowerton137]

@@riccicrozzie8204 This comment was in the spam box. I just had to manually approve it. I didn't mean to sound like an ass either, I just get tired of endless unbacked claims I also deal with it ALL DAMN DAY LONG at work 6 days a week (even Mfgs). So after working some double shifts and barely sleeping all week... I probably channeled some energy above. So thank you for following up! Next adjust adjust on both bikes (as they run perfectly) I'll find TDC and pin a advisory comment to this video. I had checked my Nihilo directions (even before I replied) so they've since added that. I have a folder on my phone where I keep digital manuals. It's helpful on the trail (if you have phone service) if things go awry.

[@ronanrogers4127]

Started to watch but when I read some of the conversation I clocked off, a bit aggressive for my liking…hope it all worked out

[@JohnHowerton137]

In the correct conversation? There was ONE commentor in the whole thread that came on talking a bunch of smack and later went back and edited his comments AFTER the conversation was over and we'd kissed and made up.. Guilty conscience? Can't please everyone, but I refuse to let keyboard aggressors take something fun like motorcycles and use it as an outlet for their personal issues while not providing any useful information about their criticisms to help others. If that makes me the bad guy, then I guess I'm the Devil 🤷‍♂️ It worked out great. 22,000 miles later and two small checks and it still works perfectly.

[@davidwaterhouse4133]

Just guesswork. Rubbish

[@JohnHowerton137]

Guesswork? “1/2 turn” is the spec. A little “engine feel” in/out adjustment test, because isn’t easy to feel a “finger tight” (a subjective tension) when setting the adjuster before the 1/2 turn spec.