Another "DIY" ktm 690 thread...

Discussion in 'Thumpers' started by Evil Invader, Jul 21, 2011.

  1. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Gonna share some things I do to my 690.

    HEY, NO DIRTY THINKIN HERE, OK?????? :huh

    :wink:

    First; Those of you who choose to follow my path, do so at your own risk. I`M NOT A MECHANIC!
    With that said, if you see me f%&k up, by all means let me now!!

    12-03-18: Rally bike build added. Skip to page 2 post 23.

    Allrighty then...
    It all started with a nice delivery from ol´ UK.
    [​IMG]
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    Then started to remove..
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    Oh, and don´t forget the music. Allways feels better to work with music in the background. :super
    [​IMG]


    Ok on with the show.
    SAS and SLS had to go. Just a lot of stuff no one needs. That has allready ben covered by MAXVERT here:
    http://www.advrider.com/forums/showpost.php?p=11512619&postcount=10360

    I did allmost the samebut went a little further. Ditched the Breather cover (alu-lid in pic below) and made my own from alu.
    [​IMG]

    [​IMG]

    Engine breatherhose now direct to airbox.
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    [​IMG]


    Here you can see the electircal connection for the sas/sls valve. I didn´t put a resistor in it, and nock on wood no flashing FI-light.
    [​IMG]
    Maybe got something to do with the ackro-map? :hmmmmm
    Dunno, it just works :augie

    Lots of stuff to come off...
    [​IMG]
    #1
  2. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Lets see...
    [​IMG]

    [​IMG]

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    Touratech folding stepplate thingy..
    [​IMG]


    Also put on a speedo from an old Husaberg (adjustable trip), homemade roadbook mount and steeringdamper (Oh joy). Sorry, no pics of the work in progress..
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    [​IMG]

    Power outlet for gps..
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    [​IMG]

    Switches in front of the saddle is for gps outlet and ignition. No more key.
    [​IMG]
    #2
  3. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Time to check the valves. Pretty straight forward job, especially if you got rid of the "spaggethi incident" called SAS/SLS...
    First remove sidecovers and airbox.
    Valvecover sits with 4 bolts. Unscrew but let them stay in cover.
    A bit fiddly to get the cover off, but no worries.
    [​IMG]
    Oops, need to check that coolant....

    Behold, the inner realms of KTM 690! (Well, parlty anyway...)
    [​IMG]


    Ok, time to get to TDC. This is what it should look like. Feel on the rocker arms, you should be able to move them a tiny bit.
    [​IMG]

    No need to block the engine with a "special tool", it doesnt, go anywhere.

    Time to measure.
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    [​IMG]

    Mine were in spec. after 10.000 km. No worries.

    Lets get it all together. Nothing fancy, just everything backwards.

    Go easy now, just 10 Nm on the valvecover bolts!! :deal
    [​IMG]


    Now pat yourself on your shoulder and got out spend your money on fuel instead of expensive workshops.
    [​IMG]

    :1drink
    #3
  4. TimFinnegan

    TimFinnegan Rally addicted

    Joined:
    Feb 15, 2010
    Oddometer:
    117
    Location:
    Germany
    Nice Ramones shirt! I see you are teaching the right things:lol3
    #4
  5. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Just trying to be a nice parent...:gerg



    :wink:
    #5
  6. TimFinnegan

    TimFinnegan Rally addicted

    Joined:
    Feb 15, 2010
    Oddometer:
    117
    Location:
    Germany
    Seems to work:evil
    #6
  7. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Ok, time for fork oil change and some "Original Gold"...
    [​IMG]

    [​IMG]

    First unscrew bolts in top tripple.
    Loosen fork top, Just loosen it.
    [​IMG]

    Remove front brake calliper (if you are on that side..), remove front wheel.
    [​IMG]

    Unscrew lower triple bolts.
    Remove forkleg.
    Unscrew fork top. Don´t worry. Nothing will go "boing" right in your face.:wink:
    [​IMG][​IMG]

    Easy, ey?
    Ok. Remove spring.
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    Time to drain oil. Turn forkleg upsidedown into a "suitable container" and let the oil flow out.Pull the piston in and out to ensure it all gets drained
    You´ll probably need to turn the forkleg around a couple of times and do it again.
    [​IMG]
    It´s not only forkoil in there if you wonder ´bout the collor....

    Right, on with the show.
    When you get all the oil out turn the fork rightways and compressed.
    Hold the piston up about 1,5 cm and add new fresh oil of your choice. I´m going 5w.
    Fill up gently and air starts to escape. Pull the piston up and down a few times.
    Be sure you don´t get the oil level below the four holes you see down the tube, or you will get air in.
    [​IMG]

    [​IMG]

    Remove excessive oil and set airchamber to your spec. Mine is 110mm. Spring out, leg compressed.
    [​IMG]
    This thing works like charm. If you don´t have one, get one! :deal

    Remount everything, do the other leg and go ride! :ricky

    :freaky
    #7
  8. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Well, if you´re doing the front, you´ll need to do the rear. Right?

    Remove rear wheel and lift the tank.
    [​IMG]

    Remove top and lower shock mounting bolts
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    [​IMG]

    remove shock linkage bolt.
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    Now is a good time to regrease the linkage as well.
    Remove shock. This step might involve some fiddling and foul language.

    Place the shock on your workbench and compress the spring.
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    Remove spring retainer
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    [​IMG]


    Remove spring. Mount new spring. Remount shock on bike. Get bike dirty. :deal
    [​IMG]
    Nice, ey? :wink:
    #8
  9. TimFinnegan

    TimFinnegan Rally addicted

    Joined:
    Feb 15, 2010
    Oddometer:
    117
    Location:
    Germany
    Man, I always wondered where to put my axis... but now I know I got the same damned holder for it:lol3
    #9
  10. bobzilla

    bobzilla Dirty Old Man

    Joined:
    Apr 19, 2006
    Oddometer:
    939
    Location:
    Lost & Found again in the Great Basin
    nice documentary, but you could at least showed how to change the shims:rofl
    thanks
    #10
  11. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Bobzilla:
    Thanks!
    I didnt need to change them shims, but might add that anyways next oilchange or somethin.

    TimFinnegan:
    It´s the small details, right? :wink:

    :freaky
    #11
  12. giodog2000

    giodog2000 Been here awhile

    Joined:
    Apr 12, 2009
    Oddometer:
    245
    Location:
    Montreal , Quebec
    Hi guys,

    I don't know where to post this but I need help.

    Today my friend and I went riding (both on 690 enduro R) , and unfortunatly my friend had a major spill and landed on the left handle. Everything is out of alignment and not sure if fork or tripples are bent or not.

    Long story short , I offered to help him check everything out and his bike is in my garage and I need to figure out how to aligne the tripples. So far I have removed the handlebars, the wheel , and about to slide out the forks to see if they are bent but one thing is for sure, the triple trees are out of alignment.

    Help please. thanks

    Gio
    #12
  13. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Saw you´ve got help in your other thread. Glad it seemes fine.
    :freaky
    #13
  14. giodog2000

    giodog2000 Been here awhile

    Joined:
    Apr 12, 2009
    Oddometer:
    245
    Location:
    Montreal , Quebec

    EDIT: All fine now,,, thanks
    #14
  15. Seth S

    Seth S Will _____ for _____

    Joined:
    Jul 19, 2004
    Oddometer:
    4,842
    Location:
    sanity?
    didnt know you could get the tail plastic in white. :clap
    #15
  16. The Letter J

    The Letter J lost in the 690 mega

    Joined:
    Aug 17, 2010
    Oddometer:
    1,089
    Location:
    Santa Maria, CA
    the stock 2010+ smc tail plastic is white, looks like this one may have been painted judging by the orange rub marks where the seat would touch.
    #16
  17. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Yes, painted it. Looked like sheit when i got it, lots of scratches and rubmarks, and wanted to see what it looked like white.
    As you may notice i haven´t bought the "real deal" white rear fender just yet....
    And it got even more scratches and rubmarks now.
    :lol3
    #17
  18. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Well, it´s that time of year when "things" gettin darker, so more light needed.
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    Before:
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    After:
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    Crappy pic, but you get the idea... Connected to the Hibeam.
    [​IMG]
    #18
  19. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    One thing I discovered on my aux light tryout trip, is that it´s bloody difficult to read the roadbook when dark, so things need to be "lighter" :evil (sorry..)

    First take your 19.99$ RB
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    Drill a hole
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    Take a leftover indicator lamp or simmilar
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    Make sure arrows point in right direction....:poser :doh
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    Fixed
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    Connect the way you prefer. I hooked up on the lobeam.
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    Let´s go racing!! :wink:
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    #19
  20. TimFinnegan

    TimFinnegan Rally addicted

    Joined:
    Feb 15, 2010
    Oddometer:
    117
    Location:
    Germany