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Old 07-09-2013, 07:29 PM   #9601
Kirkster
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Quote:
Originally Posted by poondangle View Post
I had the same problem, minus the abuse, on mine after only 500 miles. The clutch was replaced under warranty.
Never had an issue with my clutch till today. Over 5k on the bike.
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Old 07-09-2013, 07:43 PM   #9602
The Letter J
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So what is the question? Your clutch is burnt, you need a new one.

It is really easy to change and I could easily do it trailside if I had the parts... being that you are on the road, your best bet might be ordering a cheap(er) replacement (only because it is more likely to be in stock) online and having it overnighted.

EBC part #DRC205 is a complete kit to fit the 690 and there are offbrand variations on Ebay by "Outlaw Racing" for very cheap. I don't know the KTM part number for a "kit" but if you buy 3, 28, 29, 30, and 31 in the listed quantities here: http://partsfinder.onlinemicrofiche....&c=0&d=-CLUTCH you will have the same thing.

outlaw kit: http://www.ebay.com/itm/Outlaw-Racin...1a9a9e&vxp=mtr

EBC kit: http://www.ebay.com/itm/08-KTM-690-E...28e14e&vxp=mtr

EBC friction plates only: http://www.ebay.com/itm/EBC-Clutch-F...6e7915&vxp=mtr

One question for you: does your clutch lever feel abnormally stiff and go back to normal(ish) when cool?
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The Letter J screwed with this post 07-09-2013 at 07:53 PM
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Old 07-09-2013, 07:58 PM   #9603
Kirkster
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Quote:
Originally Posted by The Letter J View Post
So what is the question? Your clutch is burnt, you need a new one.

It is really easy to change and I could easily do it trailside if I had the parts... being that you are on the road, your best bet might be ordering a cheap(er) replacement (only because it is more likely to be in stock) online and having it overnighted.

EBC part #DRC205 is a complete kit to fit the 690 and there are offbrand variations on Ebay by "Outlaw Racing" for very cheap. I don't know the KTM part number for a "kit" but if you buy 3, 28, 29, 30, and 31 in the listed quantities here: http://partsfinder.onlinemicrofiche....&c=0&d=-CLUTCH you will have the same thing.

outlaw kit: http://www.ebay.com/itm/Outlaw-Racin...1a9a9e&vxp=mtr

EBC kit: http://www.ebay.com/itm/08-KTM-690-E...28e14e&vxp=mtr

EBC friction plates only: http://www.ebay.com/itm/EBC-Clutch-F...6e7915&vxp=mtr

One question for you: does your clutch lever feel abnormally stiff and go back to normal(ish) when cool?
No it does not feel stiff. Feels normal.

K
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Old 07-09-2013, 08:07 PM   #9604
Velociraptor
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This is a nice video to try and repair the clutch if you cannot find a new clutch pack.

http://www.youtube.com/watch?v=X0hnN4Hi8jE

You can lay the bike over on the left side and pull the clutch apart without having to drain the oil. Also KTM talks about some special screw or bolts to tension the plates while you unscrew the bolts holding the springs. Not necessary in my experience.
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Old 07-09-2013, 08:11 PM   #9605
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Palmstatecrawler and KTM Mitch: I've been out of town for a couple of days; sorry for the late reply but definitely thanks for the information on getting the swingarm back together. I'll pull it back apart and start over a bit from the front. It is definitely tricky!

Again, thanks!


Lee...
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Old 07-09-2013, 08:12 PM   #9606
Kirkster
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Quote:
Originally Posted by Velociraptor View Post
This is a nice video to try and repair the clutch if you cannot find a new clutch pack.

http://www.youtube.com/watch?v=X0hnN4Hi8jE

You can lay the bike over on the left side and pull the clutch apart without having to drain the oil. Also KTM talks about some special screw or bolts to tension the plates while you unscrew the bolts holding the springs. Not necessary in my experience.
I have. Lots of clutch exp on my Yamaha, so I know the trick about laying it over. Will order a clutch pack if I need one. Easy enough to change on the side of the road or in front of the motel door for that matter...

K
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Old 07-09-2013, 08:15 PM   #9607
The Letter J
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Okay, that supports your frictions being toast. If you had lost fluid in the system the clutch would not disengage, opposite of the symptoms you are having. If the lever was hard, you either just momentarily got the frictions hot (causing them to swell, which sometimes goes back to normal after cooling) or you had water in the clutch fluid that got hot and boiled. Your situation sounds pretty cut and dry... burnt clutch.

For the time being, just downshift if you feel it starting to slip, accelerate slowly, keep your speed down and try not to lug the motor... your clutch will have more mechanical advantage over the wheel in a lower gear, making it less likely to slip. Ideally you'd just stop traveling and replace it, but taking it easy might keep you moving.

I had to replace mine right at 5k miles and really should replace it again now at ~12k miles.
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Old 07-09-2013, 08:32 PM   #9608
Kirkster
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Quote:
Originally Posted by The Letter J View Post
Okay, that supports your frictions being toast. If you had lost fluid in the system the clutch would not disengage, opposite of the symptoms you are having. If the lever was hard, you either just momentarily got the frictions hot (causing them to swell, which sometimes goes back to normal after cooling) or you had water in the clutch fluid that got hot and boiled. Your situation sounds pretty cut and dry... burnt clutch.

For the time being, just downshift if you feel it starting to slip, accelerate slowly, keep your speed down and try not to lug the motor... your clutch will have more mechanical advantage over the wheel in a lower gear, making it less likely to slip. Ideally you'd just stop traveling and replace it, but taking it easy might keep you moving.

I had to replace mine right at 5k miles and really should replace it again now at ~12k miles.
Well if. Is is slipping in the morning I will order a whole new clutch pack from somewhere and get it overnighted.

Thanks for the quick response. Will find out in the morning...

K
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Old 07-09-2013, 11:09 PM   #9609
Fabless
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Preload adjust without removing shock: one solution

Quote:
Originally Posted by burmbuster View Post
Picked up the new 690 today. Stormed the entire way up there and back, over 3 hours each way. [...]

I decided to set the sag on the shock as the height was a bit high and it only had about two inches of sag from the dealer.
Took the weight off the rear wheel and started backing off the spanner nut using a piece of key stock. Got it about 3/16" up and was afraid the spanner nut wouldn't last much longer with the beating so it looks like I will have to remove the shock and adjust it outside of the bike. That sucks.
[...]


Brad
I bought this spanner wrench: http://www.amazon.com/gp/product/B00415XAH0

Using a grinder, I contoured the handle to improve its reach around the shock and trellis frame so I can adjust preload without removing the shock.



Cheap and easy.

-Fabless
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Old 07-10-2013, 12:22 AM   #9610
Oldbear
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Quote:
Originally Posted by Kirkster View Post
Well we made a wrong turn on the TAT in Utah today. I really abused my clutch in deep sand for a long time. When we finally made it back to pavement my clutch was slipping big time. In 6th on the highway anything over 4500 rpm and the clutch would start slipping. Where should I start looking?

Look in the manual and nothing. There does not appear to be any leakage from the master. I have not looked at the fluid in e slave yet. Exhausted...
Might be a stupid question but did you check the fluid level in the master?

If it was on the upper level it's probably overfilled now after the abuse. That's probably the most common reason for people burning their clutches on low mileage.
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Old 07-10-2013, 04:32 AM   #9611
burmbuster
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Quote:
Originally Posted by Fabless View Post
I bought this spanner wrench: http://www.amazon.com/gp/product/B00415XAH0

Using a grinder, I contoured the handle to improve its reach around the shock and trellis frame so I can adjust preload without removing the shock.



Cheap and easy.

-Fabless
Awesome. Thanks, Fabless
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Old 07-10-2013, 06:59 AM   #9612
Kirkster
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Quote:
Originally Posted by The Letter J View Post
So what is the question? Your clutch is burnt, you need a new one.

It is really easy to change and I could easily do it trailside if I had the parts... being that you are on the road, your best bet might be ordering a cheap(er) replacement (only because it is more likely to be in stock) online and having it overnighted.

EBC part #DRC205 is a complete kit to fit the 690 and there are offbrand variations on Ebay by "Outlaw Racing" for very cheap. I don't know the KTM part number for a "kit" but if you buy 3, 28, 29, 30, and 31 in the listed quantities here: http://partsfinder.onlinemicrofiche....&c=0&d=-CLUTCH you will have the same thing.

outlaw kit: http://www.ebay.com/itm/Outlaw-Racin...1a9a9e&vxp=mtr

EBC kit: http://www.ebay.com/itm/08-KTM-690-E...28e14e&vxp=mtr

EBC friction plates only: http://www.ebay.com/itm/EBC-Clutch-F...6e7915&vxp=mtr

One question for you: does your clutch lever feel abnormally stiff and go back to normal(ish) when cool?

Stupid question but is the DRC205 going to fit a 2012 690 enduro?
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Old 07-10-2013, 07:37 AM   #9613
Seth S
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Quote:
Originally Posted by Kirkster View Post
Stupid question but is the DRC205 going to fit a 2012 690 enduro?
My guess would be yes. But I would compare the part numbers for the stock clutch pack from say a 2010 with a 2012 and see if it is different. The clutch has always worked well so I find it unlikely that they did any major changes on it.
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Old 07-10-2013, 08:36 AM   #9614
Kirkster
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Quote:
Originally Posted by Seth S View Post
My guess would be yes. But I would compare the part numbers for the stock clutch pack from say a 2010 with a 2012 and see if it is different. The clutch has always worked well so I find it unlikely that they did any major changes on it.
I did the stare and compare and the part numbers are the same.

Parts are ordered next day air...



Thanks guys...
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Old 07-10-2013, 09:01 AM   #9615
Jarrek
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Hey guys!

Quick question: I've just received my UNI Filter (NU-1417ST) but it's not preoiled, so I gotta buy some filter oil. I decided to go with oil spray because it's much more convenient. What brand would you use? Is Motul good? I'm looking at Motul A2 right now.
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