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Old 01-28-2013, 03:39 PM   #6946
dad2bike
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Location: Las Vegas, NV
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FINALLY MADE IT!


It took me 3 weeks to get thru all 466 pages of this thread.

My Ginger has been sitting on a stand waiting for me to give her some attention.

I've gleaned about 5 written pages of items to be inspected on my bike as well as a bunch of links to videos and posts on mods and fixes. Great information from a great bunch of people!

I've got a big mountain of goodies to be installed.
One more weekend of distraction (Parker 425) and then I can start to get cozy with Ginger.
I sure hope my Big Orange doesn't get jealous. Maybe I should ride her to work since it is warming up.
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Old 01-28-2013, 03:48 PM   #6947
Baja Dad
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Quote:
Originally Posted by dad2bike View Post
FINALLY MADE IT!


It took me 3 weeks to get thru all 466 pages of this thread.

My Ginger has been sitting on a stand waiting for me to give her some attention.

I've gleaned about 5 written pages of items to be inspected on my bike as well as a bunch of links to videos and posts on mods and fixes. Great information from a great bunch of people!

I've got a big mountain of goodies to be installed.
One more weekend of distraction (Parker 425) and then I can start to get cozy with Ginger.
I sure hope my Big Orange doesn't get jealous. Maybe I should ride her to work since it is warming up.

I will call you later in the week.
I may be coming out to Parker on friday.
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Old 01-28-2013, 03:58 PM   #6948
dad2bike
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Originally Posted by Baja Dad View Post
I will call you later in the week.
I may be coming out to Parker on friday.
This sounds expensive for me.





I still have not seen a direct answer about if the 690 swing arm requires water drain holes like the EXC & adventure swing arms.
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Old 01-28-2013, 04:09 PM   #6949
Albie
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Originally Posted by dad2bike View Post
This sounds expensive for me.





I still have not seen a direct answer about if the 690 swing arm requires water drain holes like the EXC & adventure swing arms.
I'm sure it wouldn't hurt to go ahead and drill the holes. Heck, I've never bothered to drill my EXC. I just slather on some anti seize on the adjuster bolts every now and then.
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Old 01-28-2013, 04:25 PM   #6950
TheMuffinMan
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So rocker arm bearing play. What exactly is to be tested? I want to know personally but since this is one of the main known issues with the bike it'd be great to put a blurb up on the wiki about it as well.
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Old 01-28-2013, 04:34 PM   #6951
Albie
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Originally Posted by TheMuffinMan View Post
So rocker arm bearing play. What exactly is to be tested? I want to know personally but since this is one of the main known issues with the bike it'd be great to put a blurb up on the wiki about it as well.
From what I understand it's abnormal wear and scoring.
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Old 01-28-2013, 07:48 PM   #6952
meteorite
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Location: Panama SA
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FI ignition coil

Took my 09 Enduro R for a spin on the nearby beach today. Noticed a momentarily sputter earlier at full throttle 3rd gear. Not too worried then as she kept going good after that. Later, as distance between home and more fun grew, one more sputter and silence:. For the first time since I had my bike I got a FI code. Boy was I exited !!! 3 long 7 short= ignition coil issues. Ok time for payback after all the fun I had. Due to location and some other considerations, I started the long push home. Great review on my Sidi boots to follow. Made it home late (or early I should say) bit thirsty but in good spirit. Tomorrow I shall tackle the issue. Quick read in my repair manual says to check resistance between two indicated points on the coil. Thats where I'll start. If anyone here dealt with similar issue, any advice/recommendations/findings will be liked.
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Old 01-28-2013, 08:09 PM   #6953
Head2Wind
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mine did this to me out in the middle of no where this past summer.... part of this was my fault for not making sure that the coil wires were completely onto the terminals on the coil while doing PM, service and reconfig of systems. The first portion of it showed up on the trail in the midst of a 4 day ride. I managed to find it, and "fix" it, or so I thought.... I turned round on the single track that we were on and headed back out 2 miles to the road and then we rode access roads to meet up with the rest of the Epic Dual sport riders.... and 3 blocks away from the hotel right after a traffic light, engine off like a switch.. and FI codes 3-7, which at the time ment bumpkis to me on the side of the road in 105 deg F Wenatchee. I figured that there was something else wrong and so I pushed the bike to the hotel, again, still in 105 deg F. After several LARGE beers at the restaurant one of my riding buddies who is the parts manager at the local KTM store said "hey, I found the manual for my 350 online, can't find the 690, but it says that 3S-7L is a coil fault".... So we had a direction to go in to solve it... We went back to the hotel parking lot and I tore into it, pulling the right side rally tank off and the regulator so I could get to the coil without issue (coil relocated for rally tanks) and there you have it.... F'n wire had completely fallen off the coil. So I pulled the other wire off the coil and preloaded the connectors (squeezed with pliers) and made damn sure that they both went completely onto the coil terminals. Started right up, no hiccups since and its been through some fun trails for sure!
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Old 01-28-2013, 08:59 PM   #6954
meteorite
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Location: Panama SA
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Quote:
Originally Posted by Head2Wind View Post
mine did this to me out in the middle of no where this past summer.... part of this was my fault for not making sure that the coil wires were completely onto the terminals on the coil while doing PM, service and reconfig of systems. The first portion of it showed up on the trail in the midst of a 4 day ride. I managed to find it, and "fix" it, or so I thought.... I turned round on the single track that we were on and headed back out 2 miles to the road and then we rode access roads to meet up with the rest of the Epic Dual sport riders.... and 3 blocks away from the hotel right after a traffic light, engine off like a switch.. and FI codes 3-7, which at the time ment bumpkis to me on the side of the road in 105 deg F Wenatchee. I figured that there was something else wrong and so I pushed the bike to the hotel, again, still in 105 deg F. After several LARGE beers at the restaurant one of my riding buddies who is the parts manager at the local KTM store said "hey, I found the manual for my 350 online, can't find the 690, but it says that 3S-7L is a coil fault".... So we had a direction to go in to solve it... We went back to the hotel parking lot and I tore into it, pulling the right side rally tank off and the regulator so I could get to the coil without issue (coil relocated for rally tanks) and there you have it.... F'n wire had completely fallen off the coil. So I pulled the other wire off the coil and preloaded the connectors (squeezed with pliers) and made damn sure that they both went completely onto the coil terminals. Started right up, no hiccups since and its been through some fun trails for sure!
Thanks H2W. Shall check that for sure. Wouldn't be surprised if I have the same. Good fun though. Way to meet people. The locals had a good giggle as they squeaked by on old rusty bicycles and unpronounceable brand motorcycles.
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Old 01-28-2013, 09:09 PM   #6955
KC-10ENG
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I wish I didn't have to post this here but another radiator bites the dust! My day started out bad but ended well after the radiator was repaired and topped off! The test ride after the repair was 109 miles of double and single track followed up with 35 miles of slab.

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Old 01-28-2013, 11:12 PM   #6956
Seth S
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So its fixed again? My radiator was bent around a tree...got fixed and os still on the bike
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Old 01-29-2013, 05:47 AM   #6957
Albie
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Originally Posted by Seth S View Post
So its fixed again? My radiator was bent around a tree...got fixed and os still on the bike
I'm on my 3rd radiator and I never hit shit.
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Old 01-29-2013, 06:42 AM   #6958
Seth S
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Originally Posted by Albie View Post
I'm on my 3rd radiator and I never hit shit.
Send them to mylers he will fix. Remove the top fan shroud bolts and zip tie instead
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Old 01-29-2013, 06:50 AM   #6959
Yellow Pig
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Location: Kalifornia
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Quote:
Originally Posted by TheMuffinMan View Post
So rocker arm bearing play. What exactly is to be tested? I want to know personally but since this is one of the main known issues with the bike it'd be great to put a blurb up on the wiki about it as well.
Here is a picture from RoninMoto's (Noah) bike:



You can really see the abnormal wear on the roller.

Some comments made on the roller by Gunnerbuck:

Hi Noah,
It is not common for the valve clearance to loosen and this usually points to other issues... Normal operation and valve wear will drop the valves farther into their seats and thus reducing the clearances to the tappets...

Usually on the 640 and 690 when the clearances open it means that actual cam follower roller needles are on their way out and have developed slop... When it is run closer to the point of failing the cam follower bearing may quit turning altogether and gall up the camshaft lobe... With a keen ear you can usually notice a change to the tappet noise and how it emits a louder klikety klak before it does any damage... The next time you have the rollers exposed try giving them a wiggle to see if there is slop...

A couple of videos:

http://www.youtube.com/watch?v=MBwmIaa0PDk

http://www.youtube.com/watch?v=wtwCl_yGa-Y
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Old 01-29-2013, 09:06 AM   #6960
Albie
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Originally Posted by Seth S View Post
Send them to mylers he will fix. Remove the top fan shroud bolts and zip tie instead
I gave them back to KTM when they warrantied them. Fixed the fan shroud problem after the first failure. The first replacement rad just spontaneously sprung a leak 2 weeks after it was installed. The second replacement rad sprung a spontaneous leak as well last summer, but I just JB welded that fucker.
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