690R build thread

Discussion in 'Thumpers' started by Mudguts, Apr 7, 2010.

  1. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,137
    Location:
    Some were in , lostralia
    Here's my little helper getting it into position for you

    [​IMG]

    He is a certified areo space engineer likes to make sure things are spot on . Very fussy one of those micro management types
    [​IMG]


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    [​IMG]
  2. Gros Buck

    Gros Buck Beef = Packed Vegetables

    Joined:
    Jun 29, 2006
    Oddometer:
    848
    Location:
    Quebec City, Canada
    Say thanks to your helper ... :freaky

    There's an "O" ring underneath the flange ??? I'm asking because I know previous tanks (let's call EVO 1), while they had this flanged aluminium neck filler type (very early models), were leaking. However, the plastic base this aluminium filler neck is bolted today on seems more rigid.

    Thanks.

    Paul Jr
  3. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
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    Oddometer:
    2,137
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    So i did not work today cause they have not paid me Soooo i thought it was a good day to work on the rally .


    So first off I striped the RRUK tanks off and started the mocking up the tanks positions , It all went very easy due to the Scotts steering damper clamp , just
    had too re-drill the hole out too 8mm and bolt on the the rubberised bolts they are sitting about 5mm to hi but they will squash down over time , Unfortunatly
    i cant to the the key with some mods , Ill just cut down the plastic off the key and extend it , should work a treat .

    [​IMG]

    Then on with the fairing it was all to easy just un-bolt one side panel and bolt on the the new one , [​IMG]

    Here is the side with the new fairing ,

    [​IMG]
  4. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
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    Ok Its time for me start thinking about the fuel pump situation ,I'm thinking the KISS method and that would a be a vacuum pump as used on the 640 ,660's and 690 rallys to pump it in to the rear main tank and let the eletric pump take it from there .

    I'll have to use the same method as used with the RRuk tanks and let the rear tank drain a little then switch it over to all tanks

    then i will let it gravity feed from full untill the fuel light then use the vacuum
    pump to drain the front tanks in the rear as a reserve this is the simplest way i can think of , a bit of messing around with two peacocks one for vacuum and the other for fuel but it should work anyway if I'm that low on fuel in the outback i might walking anyway :lol3

    I'll just have to use a peacock on the vacuum line for the last 2-3L or so of fuel in the front tanks .

    Oh And thanks to Lukus who mentioned this a while back .

    So i guess the reserve will be about 6L or about 100km only time will tell.
  5. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
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    Location:
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    Ordered some more parts , white plastics front and rear gaurds
    More photos


    Starting to mock up exhuast
    [​IMG]

    Skinny mini about 2" skinnier at the knees then RRUK evo 1 tanks
    [​IMG]

    [​IMG]
  6. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,137
    Location:
    Some were in , lostralia
    Tanks are fitted ( good enough to ride ) just need to cut out rear frame mount and weld it on , remake the front seat mount so the next big job is the exhaust I have made the first half which i will be done again but for now I take it up to the local exhaust shop and get some thing made up for now .

    Fairing all fits nice that will be updated with a Carbon fibre 450RR fairing
    painted the low gaurd black , Order all new white plastics as the 690RR fairing needs to be painted to mach the tanks .

    Also made up some gaskets for the fuel filler as they were missing , Another little project is there is a ton of room under the
    seat so i will make a plug from expanding foam then a carbon fibre tool box \ glove box . ( i will get a photo of how much room there is )

    so that leaves

    exhaust
    bash plate ( pete640 I like you carbon one )
    reg\rec bracket just needs abolt
    krank case beather need to be re-routed up on top of the air box venting to atmosphere ( with a filter of couse )
    New tyres
    fit my other Ico
    and last but not least a fully sick sticker kit as every one know a bike is not fast with out stickers :lol3:lol3

    [​IMG]

    [​IMG][​IMG]

    [​IMG]
  7. Sol Erzenberg

    Sol Erzenberg Lost somewhere

    Joined:
    Dec 25, 2006
    Oddometer:
    1,543
    Location:
    Adelaide - North East.
    Good work Mudders..:thumb
  8. Knackers

    Knackers Polishing Turds

    Joined:
    Sep 18, 2006
    Oddometer:
    4,840
    Location:
    Drinking Vic, Qld & NSW Sewerage, Adelaide SA
    Been talking to Camo about this and the consensus is


    GAY
  9. Knackers

    Knackers Polishing Turds

    Joined:
    Sep 18, 2006
    Oddometer:
    4,840
    Location:
    Drinking Vic, Qld & NSW Sewerage, Adelaide SA
    ability
  10. Peekey

    Peekey n00b

    Joined:
    Jul 17, 2010
    Oddometer:
    2
    Hi

    Has anyone had these problems with there KTM 2011 690E seats



    The 1st is that it has cracked laterally between the 2 rubber supports above the battery. I have "fixed" this with fibreglass and by moulding a solid rubber support which sits on the battery bracket , straddles the wiring and fully supports the seat.

    The other seat problem, which is baffling me, is the next set of rubber supports either side of the airbox that sit on the frame. The seat has spread apart and is now wider than the frame. The rubber supports no longer are on the frame.

    Both these problems have occured with the stock seat and KTM power parts all day seat I purchased

    Have anyone else heard of this?
    Does anyone have a solution?
    Has anyone or no anyone who might have a solution?
  11. Hoots

    Hoots Long timer

    Joined:
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    1,711
    Location:
    Gundaroo NSW OZ
    Not personally - might need to talk to the bloke on the Wunderfest thread who fessed up to weighing 300lb ... :jinx
  12. Oldbear

    Oldbear Don't want a pickle

    Joined:
    Jun 16, 2011
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    Fin Land
    If it makes you feel any better it's quite common :D

    The topic is covered more thoroughly here: http://www.advrider.com/forums/showthread.php?t=809271
  13. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
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    Oops been in the garage some happened ...............
  14. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Yes?.... :ear
  15. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
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    It went broom broom ,for the first time in a few months
  16. frieda

    frieda gone too far

    Joined:
    Sep 25, 2012
    Oddometer:
    23
    Location:
    Germany
    Did you get back from your broom broom yet??? :D
    If so, how is the bike performing? :ear

    frieda
  17. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,137
    Location:
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    So bit of an update , have not done a lot just been riding
    So first up date
    Sxs twin chamber forks
    Second update
    All my parts have arrived

    RR UK Hi comp piston
    690RR cam
    2012 stroker crank to make it a true 690
    full gasket kit
    it just over $2500 worth of parts , and about the same for the engine build and head work

    Now I just have to drop it off to the engine builder who will be flowing the head while he builds the engine . Hopefully there are no nasty surprises . But would like a nice Hp& torque surprise

    I'm hoping the extra torque from the crank and extra power from the hi comp piston will fill the lack of low end grunt from the Rally cam but if I don't like it I can always swap it back .

    I'll be dropping off the bike next week when I fly out to Europe then 3 weeks later, I should have an arm ripping tyre shreeding animal when I come home , its to bad I won't be able to race it at condo 750 this year as I get back on the first day of racing .