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Old 12-14-2012, 12:15 PM   #6541
ktmmitch
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Joined: Sep 2009
Location: uk
Oddometer: 632
690 VMC Sidecar

The 690 sidecar is nearly complete in the fab shop at Abbotts Farbrication,and all the works is nearly done.An new airbox was fabricated to hold the UniFilter and the battery,the exhaust header was routed to the silencer and a mesh guard fitted,the car size radiator was mounted along with the header tank,and a neat VMC rad protector was water-jet cut from 3mm aluminium sheet to finish the whole thing off.
Next on the list is to complete the wiring harness connections,and get ready for the MOT test to get it road-legal.
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Old 12-14-2012, 12:45 PM   #6542
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Sidecars !!! Whoo Hooo.....let the fun begin

http://www.youtube.com/watch?v=XyRatWJ1-bk
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Old 12-14-2012, 06:49 PM   #6543
ABuck99
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SG-

Nice write up & vid- and cool work space you have there - we'd like to check out some of those other bikes in the stable sometime.

Quote:
Originally Posted by Sutherngintelmen View Post
Quit the squabbles, if you guys are going to beat the keyboard, how about drumming up something for me trouble shoot on this ill 690.

It's illogical to me that injector cleaning will make the difference given how well the bike runs as long as it's not hot. But I did it anyway.

I am curious for opinions on fuel pressure. In the first vid you can see some gas hit the floor but I'm mostly able to contain it. My thumb's not been calibrated to 55 psi -> should this firehose on me or does it seem right that I can stop it?

And for you who've been thinking of an injector cleaning it is quick and easy even for FI noob like me. I do wish I had access to ultrasonic that some of you like but since I have acetone and compressed air on hand that's what I used.

I'll take it out for a spin this afternoon - see what happens but don't think I've done anything helpful, just fooling around.

Here is the pressure vid - seems good enough?



Injector is right under the air box - disconnect electrics then out with the phillips head (butter - careful.)



Once removed you need a power source to open it if you are going to blow compressed air through it. I used a 12v battery from a drill.



You can hear the injector activate when you close the circuit.



I put it in some acetone then blew compressed air out.

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Old 12-15-2012, 06:10 PM   #6544
Sutherngintelmen
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I spent the week earning parts money in Sioux Falls SD. Nice town, fun people, good eats and drinks. They go big for Xmas - light show is downtown, surrounding the falls. Back last night, just before today. Thank you for the lots of good ideas, haven't tried any of them yet. Not a fan of shopping but after yesterday's fn mess at Sandy Hook, walking around anywhere with my 12 year old sounded lucky.

Sioux Falls SD cell photo - it's beyond the lights.



Quote:
Originally Posted by FriedDuck View Post
With all the talk about it, do you think the reg/rect is overheating? I haven't looked at it but if it's a part that's easily swapped you can borrow mine to see if it fixes the problem.
Could well be - it's a great lead. Have been reading alongat's thread from back in August with evening cocktail.

Digress - if you like such things, I highly recommend Herradura Reposado, fresh squeezed lime, Reed's ginger beer on rocks garnish with Jalapeño.

May indulge on your offer to lend a temp test swap r/r; going to be making slow progress for the next few weeks with travel and such. It appears an easy change, may be one of the parts I replace regardless as it seems known and prone.

btw - thanks for the book rec on John Boyd You ffs who like fighter pilots, unsung heroes, game changing strategic thinkers or brash ball busters might enjoy this too: "Why die all tensed up?"

Quote:
Originally Posted by Bill the Bong View Post
Is at 3/4 temp also where your fan kicks in? If so, check if unplugging the fan sensor has an effect.
Nice I can try that one eazy I swapped oem thermo for the 88c switch Quick to know if it's an issue, may be eating just enough amps to hook me.

Quote:
Originally Posted by DirtJack View Post
After it stalls does it re-start? If not, do you hear the fuel pump prime sequence? If you don't hear it, I would suggest replacing the fuel pump. Your problem sounds similar to problems described in this FI thread. I replaced mine with the CA Cycleworks FP-HUS. Problem fixed. Many other 690 owners have reported good results with this pump and it is much cheaper than the OEM KTM pump.
I'm just going to order the CA pump right peace of mind plus r&r is such a gas. Thanks for the FI read - good stuff. I think I'm going to to rig up a pressure test on current pump. Bob or Crank wrote up some ideas a few pages back. Be interesting anyway. Maybe I'll get a geyser like the spilt filter show.


Quote:
Originally Posted by dguevin View Post
Mine used to do that too!!.. It stopped doing it after a valve adjustment on my bike... I did also replace the fan swith for the suzuki ltz too over the same winter. What fixed it ?? I'd say the valves but with the new switch my fan kicks on around the 5th bar of heat out of 8 and rarely goes over 6 bars even if stopped for a while.
Not going to rule that out - haven't checked the valves. I did the fan switch swap too, kicks in quick. Spent an August week in Montreal and can assure you that generally it's warmer down here Cuz is a jazz drum major at McGill - will be skiing CA with him week after next. Fantastic town (and country) you have there.

Quote:
Originally Posted by ABuck99 View Post
SG-
Nice write up & vid- and cool work space you have there - we'd like to check out some of those other bikes in the stable sometime.
Thanks, I'm ok with words and pics it's fix that don't come ez Workspace has some sweat in it. City living gots its goods but land ain't one. Propped up under the party deck on my hill. Been meaning to take some pics and post in the bike shed thread.

Other bikes is good news ifn you're a 690 owner The only one in there that doesn't have a fix list is the Duc.

ABuck edit: just proofreading and noted you're an airhead. I'm posting sos there too - got some R80gspd improves in action. Spokes with drum is a toaser lwb '73 June build beauty.

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All pics < 6/30/12 deleted by Apple Now with SmugMug supporting ADV

Sutherngintelmen screwed with this post 12-15-2012 at 06:33 PM Reason: pics
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Old 12-15-2012, 08:26 PM   #6545
crankshaft OP
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Do any of you guys have the Euro rear fender part number, the one KTM Twins sells with the LED tail light? My dealer sent the wrong fender and I'm trying to get it worked out. THX
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Old 12-15-2012, 08:32 PM   #6546
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Quote:
Originally Posted by Yellow Pig View Post
I was just looking at this in the OC:



and was wondering if anyone has installed one of these:




Morimoto Mini DS2 HID Projector in one of these:

http://www.rallylights.com/Hella_90m...p_Modules.aspx
http://www.rallylights.com/SearchRes...CategoryID=568

You might be able to use one of these as well
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Old 12-15-2012, 09:52 PM   #6547
Biped
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Quote:
Originally Posted by crankshaft View Post
Do any of you guys have the Euro rear fender part number, the one KTM Twins sells with the LED tail light? My dealer sent the wrong fender and I'm trying to get it worked out. THX
From my archive, what I bought, fit without issues. No license plate light though, not that I care.

Part: 76508016000
Unit Price: $22.72
Requested Quantity: 1
Comment: NUMBER PLATE CARRIER TOP 08 for KTM
--------------------------------------------------------------------------------
Part: 76514040000
Unit Price: $61.65
Requested Quantity: 1
Comment: REAR LIGHT for KTM
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Old 12-15-2012, 10:02 PM   #6548
modeselector
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Location: Washington USA
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Quote:
Originally Posted by crankshaft View Post
Do any of you guys have the Euro rear fender part number, the one KTM Twins sells with the LED tail light? My dealer sent the wrong fender and I'm trying to get it worked out. THX
Here you go (google it to be sure):

76508016000 - top black carrier
76514040000 - led tail light
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Old 12-16-2012, 01:38 AM   #6549
blakrj
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Quote:
Originally Posted by crankshaft View Post
Do any of you guys have the Euro rear fender part number, the one KTM Twins sells with the LED tail light? My dealer sent the wrong fender and I'm trying to get it worked out. THX
Crank, you can find a full EU chassis spare parts manual here.
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Old 12-16-2012, 07:38 AM   #6550
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Thanks folks! I sent the number to my dealer and he sent me the stock US version
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Old 12-16-2012, 03:50 PM   #6551
Sutherngintelmen
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I tried a couple of ideas this afternoon - no fix but eliminating potentials is progress - right?

I went after the fan switch & r/r ideas because no parts required. Hooked up a volts meter to monitor flow thinking maybe an electrics drop could be root of things. Don't think so based on tests.

Here is the cold start of 15 minute idle reset. Bike doesn't get to stalling even when temps go up. Fan did kick on during 15 minutes which seemed a good indicator not electrics related and unlikely valves - speak up, but bike shouldn't idle smoothly until I kill it if purely heat driven issue would arrive with temp.

Battery at rest >13v, drops to 12.4 during ecu boot then up to 14 at idle.



Here the bike has been running 15 mins without so much as sniff let alone a cough or stall. Rectifier is pretty hot but I can touch it without burns, maybe five seconds before it's uncomfortable. Plastics were off but no breeze. Volts still > 14.



Shut off the bike, then try to restart after a couple of minutes. In this case the fan switch was plugged in.



A few seconds later with fan switch unplugged - no difference.

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There is a pleasure in the pathed woods, There is a rapture in the smoking pipe, There is chaos, where none intrudes, in the deep dell, with its thrills roar; I love not nature less, but bikes the more. Byron riding.

All pics < 6/30/12 deleted by Apple Now with SmugMug supporting ADV

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Old 12-17-2012, 11:32 AM   #6552
blakrj
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Quote:
Originally Posted by Sutherngintelmen View Post
I tried a couple of ideas this afternoon - no fix but eliminating potentials is progress - right?

I went after the fan switch & r/r ideas because no parts required. Hooked up a volts meter to monitor flow thinking maybe an electrics drop could be root of things. Don't think so based on tests.

Here is the cold start of 15 minute idle reset. Bike doesn't get to stalling even when temps go up. Fan did kick on during 15 minutes which seemed a good indicator not electrics related and unlikely valves - speak up, but bike shouldn't idle smoothly until I kill it if purely heat driven issue would arrive with temp.

Battery at rest >13v, drops to 12.4 during ecu boot then up to 14 at

Here the bike has been running 15 mins without so much as sniff let alone a cough or stall. Rectifier is pretty hot but I can touch it without burns, maybe five seconds before it's uncomfortable. Plastics were off but no breeze. Volts still.....
I'm sure you mentioned that you'd checked the earth, but just in case. I had odd behaviour, bike ran great when cold, but when it warmed up, coughed spluttered and eventually would not restart. While waiting for a pickup, fiddling around and noticed that when pressing bracket for my regulator (relocated for RR tanks) it would fire up. Tow truck arrived and I asked for some tools to remove, clean and tighten bracket. Fired right back up and I was on my way. Sorted for months until a big Euro trip. After fuel stop on day 1, bike started its coughing, spluttering and died. Stripped tanks, cleaned up frame and off I went again, only to have it happen again shortly. Repeated this 2 more times with the same ultimate result. Dead bike! So, it looked to be more than a poor earth on the frame. What it did turn out to be was the coil mount/earth, which is on the same bracket. I cleaned up the metal on the coil (where the bolts go through) and ran an earth lead (luckily had brought some electrical cable in my spares) from the coil earth direct to the neg on the battery. Has been that way since July and been without issue. Your regulator looks okay as voltage is not spiking (at least what I can see). Shouldn't go above 15V at 5k RPM. All that being said, Rod on the Sibersky Extreme ride also had odd issues and it turned out to be his fuel pump. KTM engineers have also suggested to check the TPS as a possible cause. Hope you get it sorted.
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blakrj screwed with this post 12-17-2012 at 12:35 PM Reason: Remove repost of vids
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Old 12-17-2012, 01:51 PM   #6553
ini88
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Luke - fishfind had a problem with his rectifier on this trip from South Africa up to England. Have you tried replacing or borrowing a spare rectifier to see if that is the problem? His seems to die out randomly too but while riding.
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Old 12-17-2012, 11:10 PM   #6554
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Since he reports issues at a certain temparature cut-off, I would focus next on items that is known to malfunction when heating up - coil and regulator.

Not helping much, sorry.
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Old 12-18-2012, 10:17 AM   #6555
ktmmitch
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Front Disc with Magnet Mount

We have designed a replacement solid front disc,300mm,to suit the KTM 690 Enduro which has a hole to accept the KTM EXC magnet & circlip,to line up with the M8 tapped hole in the caliper mount.
This will enable an ICO to be used without having to drill the existing floating disc,or glue a magnet on.


We also have a rear disc designed to offer as a straight replacement for the OEM item.


These are expected to be available by end January.


Another spin-off is they will fit KTM 950/990 Adventure models,all 690 & 450 Rallye.






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