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Old 07-21-2011, 02:30 AM   #1
Evil Invader OP
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Another "DIY" ktm 690 thread...

Gonna share some things I do to my 690.

HEY, NO DIRTY THINKIN HERE, OK??????



First; Those of you who choose to follow my path, do so at your own risk. I`M NOT A MECHANIC!
With that said, if you see me f%&k up, by all means let me now!!

12-03-18: Rally bike build added. Skip to page 2 post 23.

Allrighty then...
It all started with a nice delivery from olī UK.




Then started to remove..



Oh, and donīt forget the music. Allways feels better to work with music in the background.



Ok on with the show.
SAS and SLS had to go. Just a lot of stuff no one needs. That has allready ben covered by MAXVERT here:
http://www.advrider.com/forums/showp...ostcount=10360

I did allmost the samebut went a little further. Ditched the Breather cover (alu-lid in pic below) and made my own from alu.




Engine breatherhose now direct to airbox.





Here you can see the electircal connection for the sas/sls valve. I didnīt put a resistor in it, and nock on wood no flashing FI-light.

Maybe got something to do with the ackro-map?
Dunno, it just works

Lots of stuff to come off...
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Evil Invader screwed with this post 03-17-2012 at 04:08 PM
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Old 07-21-2011, 02:50 AM   #2
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Time to add.

Lets see...






Touratech folding stepplate thingy..



Also put on a speedo from an old Husaberg (adjustable trip), homemade roadbook mount and steeringdamper (Oh joy). Sorry, no pics of the work in progress..




Power outlet for gps..





Switches in front of the saddle is for gps outlet and ignition. No more key.
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Old 07-21-2011, 03:22 AM   #3
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Valve check

Time to check the valves. Pretty straight forward job, especially if you got rid of the "spaggethi incident" called SAS/SLS...
First remove sidecovers and airbox.
Valvecover sits with 4 bolts. Unscrew but let them stay in cover.
A bit fiddly to get the cover off, but no worries.

Oops, need to check that coolant....

Behold, the inner realms of KTM 690! (Well, parlty anyway...)



Ok, time to get to TDC. This is what it should look like. Feel on the rocker arms, you should be able to move them a tiny bit.


No need to block the engine with a "special tool", it doesnt, go anywhere.

Time to measure.




Mine were in spec. after 10.000 km. No worries.

Lets get it all together. Nothing fancy, just everything backwards.

Go easy now, just 10 Nm on the valvecover bolts!!



Now pat yourself on your shoulder and got out spend your money on fuel instead of expensive workshops.


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Old 07-24-2011, 05:41 AM   #4
TimFinnegan
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Nice Ramones shirt! I see you are teaching the right things
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Old 07-26-2011, 01:48 PM   #5
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Just trying to be a nice parent...



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Old 07-26-2011, 01:53 PM   #6
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Seems to work
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Old 08-27-2011, 03:47 PM   #7
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Change forkoil and spring

Ok, time for fork oil change and some "Original Gold"...




First unscrew bolts in top tripple.
Loosen fork top, Just loosen it.


Remove front brake calliper (if you are on that side..), remove front wheel.


Unscrew lower triple bolts.
Remove forkleg.
Unscrew fork top. Donīt worry. Nothing will go "boing" right in your face.


Easy, ey?
Ok. Remove spring.










Time to drain oil. Turn forkleg upsidedown into a "suitable container" and let the oil flow out.Pull the piston in and out to ensure it all gets drained
Youīll probably need to turn the forkleg around a couple of times and do it again.

Itīs not only forkoil in there if you wonder ībout the collor....

Right, on with the show.
When you get all the oil out turn the fork rightways and compressed.
Hold the piston up about 1,5 cm and add new fresh oil of your choice. Iīm going 5w.
Fill up gently and air starts to escape. Pull the piston up and down a few times.
Be sure you donīt get the oil level below the four holes you see down the tube, or you will get air in.




Remove excessive oil and set airchamber to your spec. Mine is 110mm. Spring out, leg compressed.

This thing works like charm. If you donīt have one, get one!

Remount everything, do the other leg and go ride!

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Old 08-27-2011, 04:19 PM   #8
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Shock spring

Well, if youīre doing the front, youīll need to do the rear. Right?

Remove rear wheel and lift the tank.


Remove top and lower shock mounting bolts



remove shock linkage bolt.


Now is a good time to regrease the linkage as well.
Remove shock. This step might involve some fiddling and foul language.

Place the shock on your workbench and compress the spring.


Remove spring retainer





Remove spring. Mount new spring. Remount shock on bike. Get bike dirty.

Nice, ey?
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Old 08-30-2011, 03:12 AM   #9
TimFinnegan
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Man, I always wondered where to put my axis... but now I know I got the same damned holder for it
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Old 08-30-2011, 08:31 AM   #10
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nice documentary, but you could at least showed how to change the shims
thanks
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Old 08-30-2011, 02:16 PM   #11
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Bobzilla:
Thanks!
I didnt need to change them shims, but might add that anyways next oilchange or somethin.

TimFinnegan:
Itīs the small details, right?

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Old 09-06-2011, 05:11 PM   #12
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Hi guys,

I don't know where to post this but I need help.

Today my friend and I went riding (both on 690 enduro R) , and unfortunatly my friend had a major spill and landed on the left handle. Everything is out of alignment and not sure if fork or tripples are bent or not.

Long story short , I offered to help him check everything out and his bike is in my garage and I need to figure out how to aligne the tripples. So far I have removed the handlebars, the wheel , and about to slide out the forks to see if they are bent but one thing is for sure, the triple trees are out of alignment.

Help please. thanks

Gio
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Old 09-07-2011, 01:12 PM   #13
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Saw youīve got help in your other thread. Glad it seemes fine.
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Old 09-07-2011, 01:26 PM   #14
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Quote:
Originally Posted by giodog2000 View Post
Hi guys,

I don't know where to post this but I need help.

Today my friend and I went riding (both on 690 enduro R) , and unfortunatly my friend had a major spill and landed on the left handle. Everything is out of alignment and not sure if fork or tripples are bent or not.

Long story short , I offered to help him check everything out and his bike is in my garage and I need to figure out how to aligne the tripples. So far I have removed the handlebars, the wheel , and about to slide out the forks to see if they are bent but one thing is for sure, the triple trees are out of alignment.

Help please. thanks


All fine now ,, thanks!

Gio

EDIT: All fine now,,, thanks
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Old 09-07-2011, 01:32 PM   #15
Seth S
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didnt know you could get the tail plastic in white.
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