New and improved KTM690 WUNDERFEST

[Buzztail]

Originally Posted by Mini Trail

OK need some help again. Backstory, I had the fuel pump replaced in March, then it started smoking so I replaced the piston and rings. I rode it about 60 miles and shut it off and it wouldn't restart, then it bound up. I pulled the valve cover and the wheel pin worked its way out of the intake valve rocker and was interfering with the exhause rocker.

I got it back together today and it started quick enough but is running like crap and sometimes won't start at all. When it does start it runs rough backfires a little, won't idle for long and if I give it throttle it bogs like a carbureted bike when it is still cold.

The only thing I know to check is the cam timing for the 3rd time. The engine light is not on.

Start off checking the injector. Sounds like it could be fuel related. is the pump cycling when powered up? I know you replaced the pump already, but I'd start with fuel, and spark.

[Mini Trail]

Originally Posted by Buzztail

Start off checking the injector. Sounds like it could be fuel related. is the pump cycling when powered up? I know you replaced the pump already, but I'd start with fuel, and spark.

Honestly it is acting like the pump but I don't want to go there. The pump is making noise. I checked the spark before I put it all back together. I guess I'll study up on the injector.

[MFS]

That's where I'm at right now also. I cleaned mine myself, and the 690 fired up all sweet like (previously was not starting at all) but it does stall. Changed the fuel filter, recleaned the injector and and runs poor. Stalls when decelerating/stopping, and misses when accelerating. Holding Rpm, it runs, say doing steady 80 kph, or higher. But crack the throttle and it misses.

I have checked spark, wires, everything I could myself and taking the injector out and putting it back in was the only item that resulted in a positve.

So now today I'm in the process of finding someone to do the "ultrasonic" cleaning? Or at least at more "proffessional" cleaning than I gave it. Funny though, the shops I've called so far seem to do the same, homemade cleaning style that I do, just blow air backwards through it.

Once I can rule out the injector, then I'll look at a different part I suppose...but I think it's got something to do with it...

MFS

[Gustavo.Ramos]

Originally Posted by LukasM

I'd try to get some wideband O2 readings so you actually know what the bike is doing under load at various RPMs.

Running rich can create just as much damage as running lean.

Agree, although finding such equipment with qualified technicians around here is quite a task.

[jorich]

The power wires going to the coil, the 2 spade connectors, were very corroded on my 2010. The gauge size is too small. I was have similar type of problems, it would run great, than barely idle or not start at all and no pattern to it. Just something else you may want to check

[Velociraptor]

Originally Posted by jorich

The power wires going to the coil, the 2 spade connectors, were very corroded on my 2010. The gauge size is too small. I was have similar type of problems, it would run great, than barely idle or not start at all and no pattern to it. Just something else you may want to check

I had the same problem on my 09 690r. Seemed like a fuel problem but it was those blade connectors on the coil being a little loose. They were not corroded on my bike but crimping them for a tighter fit solved the problem.

[MFS]

Hmm, pictures? Or verbal description of the wires/connectors that you mean? I couldn't find any noticeable problems with my wires, but then again, I know not what I look for Are we talking down on the right side of bike?

MFS

[blakrj]

Originally Posted by MFS

Hmm, pictures? Or verbal description of the wires/connectors that you mean? I couldn't find any noticeable problems with my wires, but then again, I know not what I look for Are we talking down on the right side of bike?

MFS

Yes, there are 2 spade connectors on the coil. Check those. Also make sure the earth is clean and not corroded/rusty

[RoninMoto]

Originally Posted by jorich

The power wires going to the coil, the 2 spade connectors, were very corroded on my 2010. The gauge size is too small. I was have similar type of problems, it would run great, than barely idle or not start at all and no pattern to it. Just something else you may want to check

Just had this problem on my 08 in the Atlas mountains. Last night she was missing around 5k rpms. I checked the spray out of the injector and it was slightly weak so I switched it out. I also changed the spark plug. Still missing today then it cut out completely and wouldn't start.

I had weak to no spark and spade connector on the coil was so loose it fell off when I removed the coil. Problem solved. I also re-sanded the grounding while I was at it.

[jorich]

Yah. I started cutting back my wires to get clean copper. My wires were black for about 4 inches. Those spades seem to get loose quite easily.

[Mini Trail]

My coil connectors were fine and I was dissapointed.

I pulled the injector but I have never messed with one on a bike before. I don't know how much fuel should come out on startup. When I turn on the key the fuel line going to the injector "chubbed up" so I figured the fuel pump is building pressure. I listened carefully to it though and it seems a bit noisy.

Cranking the bike with the throttle closed produced a light mist, I just don't know how much it should be. I do know that a bosch CIS system that just pees fuel all the time would produce a wetter output at the injector.

[crankshaft]

Originally Posted by Mini Trail

My coil connectors were fine and I was dissapointed.

I pulled the injector but I have never messed with one on a bike before. I don't know how much fuel should come out on startup. When I turn on the key the fuel line going to the injector "chubbed up" so I figured the fuel pump is building pressure. I listened carefully to it though and it seems a bit noisy.

Cranking the bike with the throttle closed produced a light mist, I just don't know how much it should be. I do know that a bosch CIS system that just pees fuel all the time would produce a wetter output at the injector.

CIS pressure is much higher, 80-120 PSI, double what the 690 puts out. Most CIS injectors are bad, so the dribble anyway

[Mini Trail]

Originally Posted by Mini Trail

Cranking the bike with the throttle closed produced a light mist, I just don't know how much it should be. I do know that a bosch CIS system that just pees fuel all the time would produce a wetter output at the injector.

I couldn't resist here it is.

[Buzztail]

Mini,
Fuel spray looks light
Pull the injector out of the holder. Divert incoming fuel to another container.
With the injector still plugged into the electrical hook up a tube and airhose to the output side. Then push some air/solvent through backeards as you spin the motor to cycle the injector. I can take some pics tomorrow if it'll help.

[MFS]

The good thing about doing things yourself, is that the second time everything goes sooo much smoother.

That said, this is still the first time, and a lesson has now been learned!

Next time, I will defineatley pull the infector screen before reverse-blowing air through it. Like ever other screen/filter, from shop vac to bike do we not always take filter out, as seperate component and clean it then?

This time however, I messed up trying to get that lil sucker out, and have punctured it

Have the injector soaking in Diesel fuel conditioner (recommended?) for the night, will put the screen back in tommorrow, reinstall it all and try it out! Small puncture, but it can't run any worse! Will try to order injector screen kit tomorrow. um, if there is such a thing.

Did check the spade connectors on the coil, the rubber housing on one was loose, and rubbed through by a rad hose. Pinched it on a bit tighter and hopefully that and a super clean injector will make a difference....

Gonna be "extra ready" for spring...

MFS