25,000 miles with Luke and Nick

Discussion in 'Ride Reports - Epic Rides' started by Fishfund, Jan 21, 2011.

  1. BordenBmw

    BordenBmw TheFrenchRider

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    It took longer than expected to receive your bikes but they made it OK, that’s always a good thing. Now let's see some riding,:freaky good luck on your adventure, I’m subscribe.











    #81
  2. elite-less

    elite-less Been here awhile

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    Great! Now on 2 wheels!
    #82
  3. Skrow

    Skrow Been here awhile

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    Congrats on getting the bikes out of hock and on the road!

    Can wait for the MRR to begin!:clap:clap
    #83
  4. Fishfund

    Fishfund Been here awhile

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    Lansing, MI
    Thanks :1drink
    #84
  5. Fishfund

    Fishfund Been here awhile

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    So we finally got the bikes. They were only 3 1/2 weeks late, whatever. Let's get out of here and head to Namabia. Well 100 yards out of the BMW dealership, my bike quits. It acts like it ran out of gas, which is funny cause I know that I had 2 gallons in it at least. I know this because when you ship your bike you are supposed to empty the tank and I may have not completely emptied it. I assume the shippers must have emptied it some how for me. After all, the crate was completly missing three sides when it showed up and Nicks bike had oil around his filler cap like someone got in there and took a sample of it.

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    Luckily Mr. Nick has a spare gas can and takes off to find some gas for me.

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    I have three different tanks on this bike that all feed to the same fuel pump. How do you run out of gas with three tanks?

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    I put two gallons in and we take off for Cat and Moose (the place we are staying.) It feels so good to finally be on the bikes and to drive on the wrong side of the road. We make the 4 mile drive and I notice my bike feels a little weak on the way there, but don't think anything of it. Right before we get there my bike stalls while going about 20 mph, but I hit the starter and it fires back up. I didn't even have to put a foot down. The workers open the door for me and I try to drive the bike inside. I mean the door is plenty wide, I just can't keep my bike running. I stall it about 6 times and restart it trying to drive it down the hall and up the steps. It's not me being a bad driver, the bike is just acting like it's out of gas again. Once again I don't pay any attention to it as I am distracted by all of our friends cheering for us that our bikes have arrived. A celebration is in order and we all go to the local supermarket to pick up meat and veggies for a Braai (barbeque)

    The next morning we get up with plans to leave once I am done putting my bike together. You see, my bike build up was pretty much a last minute thing. The last two weeks before I left, it seemed like I had at least one package come in the mail per day. My mom can attest to that. (That's right, I'm 27 and was staying at my parrents house.) Moving on...so once I did the last minute mods to my bike, we geared up to do a little cruise of the city. I pushed the bike down the hallway and hit the starter. It wouldn't start. I tried it over and over again. The first two tries it popped once or twice, but that was it. Now I'm getting nothing. I let the bike sit and try an hour later. Nothing, I guess we aren't leaving today...

    I pull the bike inside and put my hand on the tank, trying to feel a vibration from the fuel pump. I hit the on button and don't feel the vibration. Ok, I think. Broken fuel pump. This is a common problem for 08 KTM 690's. Do a google search and you will find this out. It is in fact the reason why I tried to buy an 09 vs an 08. However, when I drove 16 hours one way out to Rhode Island earlier in the fall to buy an 09, I discoved it was actually an 08 when I looked at the title. The owner claims it was an honest mistake, and I believe him. He dropped $500 off the price and I hauled it home in my Escort Wagon crossing my fingured that I wouldn't have any problems with it in Africa.

    Turns out I do have a problem, but problems can be fixed right?

    This is the story of the next 3 days.

    We start taking plastics off and empty the tank.

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    Once the tank is emptied and the pump is pulled you have to figure out how to very carefully pull the 2-3 feet of corrugated plastic tubing out of the tiny hole without kinking anything. Very difficult.

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    Once the hose was removed we found this. A KINK IN THE HOSE!!!!

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    This is awesome, this is good. Fix the kink and we should be good to go. This explains why the fule pump won't buzz. The line is kinked and already pressurized. It also explains why when the bike when it does run feels like it's running out of gas. Ok, good. Now lets fix the kink. John at Rally Raid, http://www.rally-raidproducts.co.uk/ says this has happened to him before doing a tank install. He tells me over Skype how he fixed the line. You use pliers to get the kink out then you take a hose with a bigger diamater than the corrugated tubing and wrap it over the Kink. Apply small zip ties over the rubber hose and the kink is fixed.

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    We put the bike back together carefully not rekinking the corregated line. I turn the key and it fires right up. Problem solved. Now we can load up to leave. 20 seconds later the bike starts to caugh and dies from what seems like running out of gas. The rest of the day we trouble shoot this problem. I post my symptoms in the 690 thread on ADVRIDER and start getting suggestions from other 690 owners. Everything I try does not work. I keep getting more and more basic with our tests until at one point we have just the fuel pump in a bucket of gas with alligator clips going straight to a battery. It seems to run the pump strong for 3 seconds then peter off. Good, this is the problem I think. I drill some more holes in the plastic housing where the fule pump sits, and repete the test. Now there is a steady flow. Problem solved. The holes allowing fuel to the pump before were too small. When I installed my Rally Raid tank kit, I must have not drill a big enough hole to allow a steady flow of gas to the pump. I put the bike back together and start it up. It runs for about 1 minute and I am convinced we have fixed the bike.

    Nope, around the 1 1/2 minute mark the bike start to drop RPM's and stalls from lack of fuel. We are back at square one. Now I install the pump and attach the alligator clips to the electrical lines comming from the pump directly to the battery.

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    I then pull the fuel line right before the injector on the fuel body.

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    I connect the other ends of the alligator clips to the battery and watch the fuel flow. It is a strong constant stream. There is plenty of fuel pressue. Hmm...I start the bike and it dies again in 20 seconds. I pull the injector out and watch it shoot an intermintent spray of fuel. Everything looks good there too.

    This is the abridged version of the story. The actual time frame here is 3 days of wrenching. I can't remember anymore details, but I know their were tons more tests. You wouldn't believe how many times we gave each other fist pumps conviced that we solved the problem, but the end led to this.

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    We did our best, but now it is time to get the professionals. We towed it downtown through heavy traffic and on the Interstate to the KTM dealer. You wouldn't believe how easy footpeg to footpeg towing is. I wrap the end around the footpeg once and stand on the strap. I could steer one handed and film with my other hand on the way there. (Towing video soon...?)

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    Kevin is the main mechanic at Cape Town KTM and he really seems to know the bike, so I hope they can sort this out. The problem is they are really busy and at first said they can't get to it this week. Next week Kevin is on vacation so that puts it at almost two weeks out just to take a look at it. This is not good. Kevin knows we are in a bind and said he was going to try to sneak it in. I asked him if at least minimal he can plug it into the computer. If the computer shows nothing wrong, then any mechanic should be able to trouble shoot it and get it running. The BMW guys are over the top helpful here and they said they would take a look at it for me if I want.

    So that's were I am right now. It's been at the KTM dealer for two days now. Kevin said on the phone today he was going to get a look at it this afternoon, so in the morning, I'll go down there and talk to him about it. It would be nice to get on the road soon. As much as I like the Cat and Moose, I think I will like camping for a change.
    #85
  6. GypsyWriter

    GypsyWriter Yup, I'm a girl.

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    Funny, I was looking for your thread over on the KTM section and couldn't find it, now I did. :dunno

    Good luck figuring out what the problem is. Camping in Africa should be interesting - instead of bears getting into your tent it'd be hyenas, lions or warthogs (or elephants getting ON your tent). Should be an adventure at least! :thumb

    Btw, nice tow line. :lol3
    #86
  7. Dorzok

    Dorzok Long timer

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    luke,
    you try running the bike with the cap open? sounds like you're creating a vacuum inside those auxillary tanks and it's not letting the fuel flow. might be why it pumps in a bucket but not when you stick it in a closed system.
    #87
  8. pyrate

    pyrate Walking the plank

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    Just found your RR and was about ready to post the same thing. When I installed a larger tank on my Honda 650 the fuel cap was not vented. It had a hose but the center of the cap was not drilled out and it would run about 3 mins at idle and die every time.
    #88
  9. Fishfund

    Fishfund Been here awhile

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    We thought of that too. I ran the bike with the main take gas cap off. We have done so many tests, I can't remember if we had the aux tanks caps off, but they are vented caps.
    #89
  10. pyrate

    pyrate Walking the plank

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    And the vents are giving proper airflow? I wonder if there is some sort of baffle or diaphragm that got tweaked during shipment. The bikes were flown correct? So rapid pressurization changes of the aircraft up to about 8,000 ' or so.

    Did the bike run at home w/ the aux tanks w/ no issue?
    #90
  11. Stewart5533

    Stewart5533 Been here awhile

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    North Pacific Paradise.
    What a load you guys have been going through, I hope you get it all sorted out soon. Good Luck, cant wait for the adventure to start..
    #91
  12. Fishfund

    Fishfund Been here awhile

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    Hey, good news!! I just drove my bike back from the dealership. It ran fine the whole way. I'm going to change my oil now and go for an extended ride to see how it acts. If everything looks good, we take off in the morning.
    #92
  13. GA. DUALSPORT WANTAB

    GA. DUALSPORT WANTAB Long timer

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    :clap Hope it runs good, because I'm looking foward to an epic RR. :lurk
    #93
  14. GypsyWriter

    GypsyWriter Yup, I'm a girl.

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    Well it's about frickin' time!! :clap

    Did they tell you what the final problem ended up being?:ear
    #94
  15. Fishfund

    Fishfund Been here awhile

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    When they plugged it into the computer they said there was 8 error codes.
    I did some mods by removing the Evaporating Canister and the SAS stuff. I also took off the airbox and put on a foam unifilter along with a new exhaust to let the bike breath better. So the bike was running extra lean. The dealer installed a Avacovik sp? map so now the bike runs better. But they think the problem was clogged injector. I rode it around probably 20 miles today was zero problems.

    In the morning we take off for the southern most point of Africa. Cape Agulh
    as
    #95
  16. GypsyWriter

    GypsyWriter Yup, I'm a girl.

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    *bump*

    So, how goes everything? Got pretty quiet suddenly. :ear
    #96
  17. ini88

    ini88 Been here awhile

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    He is having fuel related problems. Trying to resolve it on the 690 mergefest thread. Sucks, and I hope he resolves it too soon. I hate that feeling of uncertainty.
    #97
  18. Fishfund

    Fishfund Been here awhile

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    We thought we had it fixed, updating right now to explain what happened.
    #98
  19. nrader

    nrader Adventurer

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    After two days at the KTM dealer Luke's bike was ready to ride. Many tests were performed trying to troubleshoot the problem. But, we are still not 100% sure what was originally wrong with it. They cleaned the injectors, and remaped the fuel system. Then they let the bike idle for 15 min and took it for a test ride. Everything looked good.

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    We did some last minute tweeks to the bikes that night and packed up to finally start our adventure. We were pumped!

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    It was a good thing we were leaving too. I was starting to get a bit too comfortable with my belongings and was leaving valubles vulnerable when I went out.

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    Woke up the next morning and said some goodbyes to friends we've met here over the last month. Nathan (One of the workers at our hostel) was devestated to see us leave. That's probably a lie. I bet most are excited to have us get our bikes out of the courtyard.

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    Boy did riding our bikes again feel GREAT! We've been couped up in a hostel for so long, waiting to accomplish a dream, that we felt absolutely free. We woke up early and headed for Cape Agulhas, the southern most point in Africa. Everything just felt right. We even have communication systems so we can crack jokes while we ride. We were amazed at how clear we could hear each other. We hit 90 mph and could still hear with no problems. 30 miles from Cape Agulhas I was clearly able to hear luke say, "Nick, my bike just died". I thought he was just joking with me. He wasn't. The bike rolled to a stop on the side of the road with the same symptoms as earlier. We decide to take one shot at fixing it. Luke is getting really good at knowing his way around his bike.

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    We did find some junk in the tank by the fuel pump. Maybe this was the problem?

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    It wasn't. We put the bike together and see if it will run again. But first we figured we would sneek a picture to make it look like we were on real adventure roads and broken down in the middle of nowhere.

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    After we put the bike together, we tried to start it one last time to see if it wanted to run. It didn't. Luckly (not sure that is the right word here) we were only 100 miles from Cape Town. So we called our friend Steve. Steve is a real good guy who transported our bikes from the airport to the BMW dealership. Good thing we had a satalite phone.

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    Steve left right after we called. Which was awesome considering we were two hours away and it was a Sunday afternoon. We had some time to burn so we figured we would go to the beach.

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    Who needs water and sand to lay out and get a tan. People underestimate how well the side of a highway works for getting tan. And by tan I mean burn. After two hours of sunbathing, Steve was there.

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    We loaded up the Luke's bike and headed home. AKA The Cat and Moose Hostel. All of our friends were surprised to see us back. Tomorrow we will tow the motorcycle to the dealership and see what they can find. Hopefully we can figure it our and get on the road soon. I think we've seen enough of Cape Town. Luke is probably getting sick of racking up bills here. The tow cost him $200 USD.

    Here is a video Luke made of working on the bike. It shows the mood we were in pretty well.


    <iframe src="http://player.vimeo.com/video/19653694?color=ff9933" width="670" height="377" frameborder="0"></iframe><p>The on going problem of the fuel pump on my KTM 690.</p>
    #99
  20. Not Fragile

    Not Fragile n00b

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    As much as it must seem to suck at this point for you guys, many of us following your ride would give our left nut to be there with you. Awsome coverage, great vids...ride on (when fixed)
    Stew