KTM 690 Oil Leak - Countershaft Seal Replacement

Before heading to a 2500 mile journey, I changed my sprockets and chain, new tires, etc. While down there, our chase truck took care of lubricating the chain each night. I started noticing drops of oil running down my kickstand and attributed it to too much lube. Later on after several washes, I still had the problem and in Moab last month it was determined I had a bad countershaft seal. I ordered the parts and replaced them as shown in the video. However, in the process, I noticed my engine sprocket nut was loose, but retained by the keeper. I did not use a torque wrench
(80nm) and I did not use Loctite 243 on the nut threads. The o-ring, not being in compression, was allowing oil to seep out along the shaft. Lesson learned. I took the nut back off and did it properly.

[@AssassinSam7]

DIY mechanic here. Great video! Helped me diagnose and repair the same issue on my 2020 Svartpilen 701. Never knew that they swedged the washer like that; surprised me when I got to that part on mine.

[@everydaybiker]

Good video, appreciated. Not that it's a complicated job. It's just nice to watch someone thats done it a few times.

[@rossvlogs7015]

Hi, the problem was caused by loose sprocket nut. It must press spacer bushing with o-ring. O-ring was your leaking place. Loose nut may also damage counter shaft splines. So problem may happen again soon. Use locktite 243 and use torque wrench not hammer :) Regards!

[@telerover]

RossVlogs I'd have to agree with you. I dwelt on it last night. I might have fixed the leak and saved a lot of trouble, and $60 by just tightening the nut. but... I'm getting ready for a long trip, so that is one less thing. thanks for confirming my thoughts!

[@telerover]

RossVlogs, I took the nut off, added Loctite 243 and torqued it to 80nm. I think I only had about 60nm, doing it on my own. I also found a pair of channel locks that would grab the retaining washer and swage it over without hitting it with a hammer.

[@rossvlogs7015]

telerover now you are sure that your trip will be fine. In my words about the hammer I just thought last moment of tightening the nut on your vid. I think more secure way to lock the washer is use hammer like in my vid. Btw. thanks for appreciate and link to it.

[@chazzer666]

We Ha just figured this out. Came back to post it in the comments and saw you had already posted it. Wish I'd seen it, would have saved me a bit of time!

[@rossvlogs7015]

Well, you saved your time either not reading comments on youtube :D

[@raymanvonmetal8559]

I thoroughly enjoy your videos! You’ve saved me lots of time doing upgrades on my 690. Cheers from Lake George, NY

[@roastchicken9143]

Just been through this with my Husky 701 (basically the same bikes your 690), and I think you'll find that the front sprocket seal was leaking BECAUSE your sprocket nut was loose. Two tips to help avoid this happening again. Apply some threadlock when you attach the sprocket nut, and also torque the nut down properly. The front sprocket requires 80 Nm of torque which I think is a lot more than you just did with your 690. These details are all in the factory specifications and are not my opinions and certainly resolved my small leak, which like, I initially believed was chain lube running down the engine case.

[@tonymarchant9083]

Yes I have read this too.

[@Andrihapes]

Great job. Thanks!

[@Shawn-in-da-Canyon]

The sprocket may also be slightly to thin to keep the seal pressed in.

[@grandview58]

That was brilliant I learned something , I noticed you have an after market sprocket on the rear , my enduro came with a 45 tooth standard I wanna go 42 I live in Australia long distant trips on black top into South Australia then onto the gravel , funny thing I have a 15 tooth on the front

[@telerover]

Salt bush Bill you can put a 16 tooth on the front without having to change the chain or rear sprocket. that would be the same as a 41 or 42 without the wear on the 15. my composite rear sprocket is a couple teeth larger, it's the smallest they can make with that type of construction. I like a lower idle speed for riding in the mountains here in Colorado.

[@ignacioa4272]

By the way, I usually prefer awesome single cylinder engine sound to music in your videos. Music may be good instead of high speed wind noise (only), but just sharing my preferences in case it helps. Great work and adventure videos

[@telerover]

I appreciate your input. Its tough to figure out what to do on my long ride videos. I only get an average of 8 minute watch times,but I am not looking to create viral videos, just provide the ride.

[@mmelling4410]

Very very good. Thankyou

[@fyreblade1262]

Backyard mechanics... Gotta love em :) Nice job just try to be a little more careful with all the hammering etc. Also torque down stuff properly, especially a sprocket nut. Hold on to the rear brake 100NM.

[@telerover]

Thanks for the tips!

[@ignacioa4272]

great work and videos Thanks much for sharing thinking of buying a Husquarna 701enduro

[@RickyZ6831]

Humbly asking, is the little black O-ring suppose to place under the brown shaft seal? I thought it supposed go seat under the spacer within its groove by the diagram. I am quiet confused now on where should I put it.

[@StonedSpoon]

Is it possible to get the links to the parts you ordered? I want to do the same replacement and there’s a lot of websites with a lot of parts

[@r6parker]

www.ktmpartspro.com/oemparts/p/husqvarna/75033010010/repair-kit-output-shaft-690

[@r6parker]

Part #: 75033010010 Use any website you like, I went with KTM Parts Pro.

[@telerover]

I use KTMpartspro.com or Rockymountainmcatv for parts

[@stefanie_m466]

motorex bike grease 2000 eh, am i reading correctly ??? 80Nm torque for nut engine sprocket and 243 loctite haha, i don't believe that.

[@roastchicken9143]

Straight from the Husqvarna workshop CD.

[@greatfallskam]

Hi telerover. When I Google anything about my KTM 690, your wonderful videos show up. Thanks. I suspect I may have a countershaft leak on my 2018 KTM with only 3,400 miles. I wish I could post some photos and get your opinion.

[@telerover]

Thanks for watching my vids!! is your countershaft nut tight? Have you changed the sprocket since new? If the nut is loose, a lot of oil will get on your chain and under the bike. If not, it could be residual oil from your 1st oil change.

[@greatfallskam]

@@telerover I am second owner of my 2018. Purchased at 2,400 miles. So I am assuming same original front sprocket. I check the big sprocket nut to make sure it was at 80 Nm. I think just residual chain oil and spring crossings. I could send you some pics, but I don't think there's way to send through KZbin. Anyhow, thanks. Keep up the great videos.

[@greatfallskam]

@@telerover Hi Telerover and Deacon. Well I cleaned my sprocket area to see if it was just chain lube or engine oil. Looks like I have a very slow countershaft seal leak. So it wasn't residual oil from my last oil change. I am suing stock sprocket. I checked my chain sag, sprocket nut torque, and oil level. All checked OK. So now I am waiting on parts. By the way, did you ever figure out which part failed on you? Was it the O ring?

[@kyleberkeley4557]

Do you have the part number for the seal kit please?

[@telerover]

look at video frame 0:21. Its 0050000946. Thanks for watching!

[@kpsmith4241]

will this fit the 701 as well?

[@telerover]

Kracker I'm not certain hiw much the LC4 motor has been changed on the 701, but almost all KTMs use the same seal.

[@dominicryan9739]

I just went to do mine on a 2010 690SMC due to apparent oil leak from that location and found the same thing, the sprocket nut was finger loose! No wonder it was leaking! Scary. Locking nut detent also looked horrific so definitely was previous owner job, no way KTM had factory locknut detent looking that poor. My sprocket also had a double-sided integral rubber bushing thing which was molded through the through-holes in the sprocket which was broken, so the outboard side of it just fell out as soon as I took the sprocket cover off. I'm not sure what it's purpose is. I noticed that yours is not present, but maybe your front sprocket is aftermarket.

[@telerover]

I'm glad you discovered that! Use a hole saw and cut a hole in the cover so you can check on it, or get a #Vanasche case saver. The stock sprocket have the rubber damper which reduces chain noise. It is not necessary. They don't make that in a 14T.

[@dominicryan9739]

@@telerover thank you!

[@dominicryan9739]

One small tip I could add for others: my bearing/seal driver kit did not have a driver with a big enough ID to clear the countershaft, so I just used to sprocket itself with the boss facing outward (i.e. not how it is actually installed). That gave a nice flat surface to hit the oil seal and also automatically stops it once it is flush with the case since the sprocket starts to hit the case.

[@dominicryan9739]

I also did not have a fork tube driver from a Bultaco or a Montesa :D

[@maariog.3801]

Ktm duke 790 2020 rok,przejechane 10tys km. Dwa razy wymieniane oring,tulejka oraz simering.Ciagle leje się olej.Masz jakiś pomysł jak to naprawić?

[@telerover]

proper torque?

[@telerover]

see RossVlogs' video which shows the proper torque specs. I was treating my change like a field repair. kzbin.info/www/bejne/kJqzi6qCrNmcacU