KTM 690 Adventure (re)build

Discussion in 'Thumpers' started by mrwwwhite, Oct 12, 2014.

  1. mrwwwhite

    mrwwwhite Been here awhile

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    Hi, after riding a '09 KTM 690 Enduro R for more than 25k throughout Central Asia, my frame fractured badly in Tynda, the mid point of BAM road (Baikal Amur Mainline).

    One year later I managed to get a replacement frame so I decided to start this rebuild thread in order to cover the actual rebuild but also a lot of mods and improvements to this awesome bike, arguably the best adventure base available at the moment.

    First I made this clip to cover the initial fracture but also the time-lapsed rebuild and I will continue to make a full write up with lots of pics.


    [​IMG]


    Enjoy!




    Thread Update:

    First 8 pages will cover the rebuild and all sorts of upgrades to the 690 Enduro like:

    - 275mm Fork revalve and 300mm extension using KTM EXC parts

    - 275mm Shock revalve and 293mm extension using SKF sealhead

    - Rocker Arm replacement and Rally Camshaft upgrade

    - Airbox mod and the design of a new CF Rally airbox (WIP)

    - head bearing replacement

    - Side stand sensor eliminator, lowered Pivotpegz, LED Blinkers and Relay

    Then from page 9 onwards I'll build one of these:

    [​IMG]

    Jump to the beginning of the build.

    #1
    Wayne Jenkins, Y E T I and Ramdog like this.
  2. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Great Video. Care to share with us what Ama's airbox mod was or share a link or post?

    Dirty
    #2
  3. mrwwwhite

    mrwwwhite Been here awhile

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    Let me just search for the exact post in the 690 and TuneEcu thread.
    You just make 2 holes on each side of the snorkel. Optionally you can put some hoses pointing backwards or down if you are stressed about river crossing capabilities.
    This + EVO1 map with his throttle map + foam filter and exhaust and you have a smooth beast ;)
    The other mod is related to the snorkel to airbox mount (two bolts). Some including myself experienced problems with the threaded inserts in the airbox getting detached. If you put a bolt from inside of the airbox through the threaded insert and then a nut to fix the snorkel.
    #3
  4. Beta450

    Beta450 Been here awhile

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    Well done.:clap
    #4
  5. gen

    gen Been here awhile

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    Loved the video! Amazing that you rebuilt the bike from the frame up. Did you change any connectors on the wiring loom? The ktm connectors are not great.

    How about a change to a MOSFET R/R?

    Also keen to hear about the fork rebuild. Mainly I am interested to hear about the EXC internals vs what RRUK is selling in their 300mm kit.
    #5
  6. Dotbond

    Dotbond Africa, Africa

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    #6
  7. mrwwwhite

    mrwwwhite Been here awhile

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    There you go:

    http://advrider.com/forums/showthread.php?t=685657&page=11


    Cheers Gen,
    No connectors were changed except for the ones I got rid of: SAS Valve and US Canister. I also unmounted the side stand switch and put a 2.2k Ohm resistor instead.

    The Mosfet is a nice upgrade but I would say not essential. You cannot generalize Fishfund's RR problems or LukasM alternator's problem IMO. Sometimes bikes get broken. What I'm trying to say is that alterantor or RR problems are far more seldom than rocker arm bearing problem for example.

    There is an awesome suspension thread here
    and I plan to do a full write up about the extension.
    The 08-11 RRUK extension kit is basically just that... EXC rebound adjusting tube, piston rod and 4.8N spring. The only reason I bought them directly from KTM was the price.
    The 12-13 models have a slightly different fork (compression adjuster on the side) so I'm not sure the EXC parts fit right in.
    The extension is awesome though I totally recommend it if tall enough.

    Hey Trev,
    Yes the PHDS system is compatible with all KTM models except big 990, 1190 etc.
    They come with medium elastomers (yellow) but people that used them recommended green (soft) ones. So you can buy them separately.
    Available from XTRIG or OEM WP through KTM dealers.
    #7
  8. Bill the Bong

    Bill the Bong Supern00ba

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    I bought the RR extension kit. I have a 2011, but it has the 12/13 fork. I needed to get a different kit from them than the earlier models. To me that means that the EXC parts are not universally plug and play.
    #8
  9. mrwwwhite

    mrwwwhite Been here awhile

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    Like I said 08-11 can use the EXC parts but the 12-13 have slightly different forks so your option is to take the RRUK kit. To be honest I recon is a length related thing and the only difference is the rod and rebound adjuster length not matching the EXC ones. Maybe. I'm positive the spring is the same. I'll check the microfiches and see what I can come up with.
    #9
  10. divimon2000

    divimon2000 Been here awhile

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    Wow, cool to watch, thanks!


    Sent from my iPad using Tapatalk
    #10
  11. Bushmaster1111

    Bushmaster1111 n00b

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    Cud is to you, well done and inspiring to watch!


    Bushmaster
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  12. LukasM

    LukasM Long timer

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    Very nice work on the rebuild and great way to document it! I bet the whole thing took many many hours, way more than you anticipated in the beginning. At least that's what always happens to me... You are lucky that you've got a lady by your side that does these trips with you, and even helps you with messy composites work! :freaky

    The BAM riding looks very familiar as well, except that we had lots more water everywhere last month. It is a seriously rough track that is hell on bikes, whatever is not bulletproof will fail out there.

    Do you like the Rally cam now that you have done some testing? I really liked the liveliness, low end, and wider gearbox of the 690cc EFI engine a lot more than I do my current 654cc Rally engine, hopefully I can get some of that back when I swap the cams and gearbox soon.
    #12
  13. mrwwwhite

    mrwwwhite Been here awhile

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    Thanks guys!

    Cheers Lukas!
    It's hard to say :) After one year I just rediscovered this bike and I'm enjoying it again. I cannot compare cause I don't have a reference anymore. Like I said it's hard to remember something you rode one year back (even it was for over 25k). I like the current setup especially the new suspension (I cannot imagine how awesome should a conevalve CC front end should feel).
    Too bad you had issues with yours through central asia but your find in UB was just incredible. You just got yourself a priceless classic ;)
    BTW do you think the 690 EFI engine is compatible with the 690RFR. I mean if you want can you use parts from a regular 690? like gearbox and such? Is the whole engine compatible like bolt on swap. I know the frame is 95% identical and the 2 engine mounts are a bit different from the 690 to the RFR bikes (cast vs billet).
    #13
  14. LukasM

    LukasM Long timer

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    Yeah the full travel EXC forks should feel nice and plush, and be good for travel as they are so easy to service. My Rally closed cartridge forks are quite harsh but they are also in serious need of a full service, and finding the tools was impossible anywhere between Europe and Korea. I finally had some shipped to me from Adventure Spec so hopefully they will get better when that is done. According to Lyndon the cone valves really only have an advantage when you go very fast, he himself ran the stock CC ones for most of the Dakar and now on the trip, even though he has a set of CVs at home.

    BTW unless you are doing more technical and slow riding I would always go with lower offset on the triples, for better high speed stability. The Rally is in a different league to the Enduro in that regard, and the key differences are the triples (20/22mm) and longer swing arm. This is especially noticeable when you start pushing the bike harder or you get into deep sand.

    The engine is to a large degree the same between E/SMC and the Rally. The differences are cam, gears 4-6, the flywheel and the clutch. All of it will interchange so you could simply put a Enduro engine in a Rally or vice versa, as long as you swap the flywheel.

    My bike was a lucky find in some ways, in others not so much. I've been having serious oil burning issues from the start since it was run with a hole in the airbox before I got it. This has gotten progressively worse and is now at about 1 liter per 100 km. The gearbox also has an issue in neutral, the dogs are catching so it can't spin freely. Fine as long as you always leave it in gear but a serious ball ache on those cold mornings on the BAM and Old Summer Road in Siberia when I flattened the battery several times before the carbed bike would run properly due to clutch drag....

    I was planning on rebuilding the engine now in South Korea but I can't get the bike out of customs and into the country because it has a Mongolian license plate. So now I have to try and figure out how to get it registered in Austria even though I'm not there. Oh well, the challenges of RTW travel.... Luckily time flies quickly here in Seoul and I've met plenty of nice people (girls)! :D
    #14
  15. losiu

    losiu wheelie addict

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    Hey mrwwwhite,

    Our mutual friend who we have both hosted during his 6-month trip recently said we should meet because you're also a 690 freak like me.
    He was totally wrong. I'm nowwhere near being as much of a 690 freak as you are :)
    But it would sure be nice to meet one day.

    Great video, solid pile of information and excellent adventures. Thanks.
    #15
  16. mrwwwhite

    mrwwwhite Been here awhile

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    To bad you have issues with your RFR but as you describe it (the 690 E compatibility) it's easy to solve them. If you rebuild the engine would be nice to make a write up (especially with the 690E similarities). There's inmate here who is rebuilding his engine also (690 SMC)
    With your expertise and Lyndon around you'll have that monster back in no time ;)

    I know the OC forks are actually quite plush and easy to maintain compared to CC especially if correctly setup. I'm wandering if a dual staged or more progressive scheme like the rally bikes have, would be more suited for this type of bike also. At same point an inmate helped me and did a comparison between the 500EXC shimstack scheme (I currently have) and the 660RFR (the last to have OC, but probably the principle extends to later models also).
    Ahhh the elusive magic carpet :))))
    The type of riding (including the rally event) we have around in the mountains is perfect for the 24 offset but at the same time it makes sense with 22 one for crazy fast roads or sand.
    It was just a bit frustrating at times with the limited angle and that is largely changed with the 24 offset.
    I hope you manage to solve the paperwork and have a blast in Korea! ;) what is the next destination? SE Asia?


    Cheers man, glad you've enjoyed the vid. I really love being a 690 freak :D we all do right? You have to once you own one. Imagine what the RFR does to you... look at Lukas or Lyndon :evil :freaky
    Ron is such a nice guy and we really enjoyed his presence. We definitely should hook up in the future. We're pretty close actually ;)
    #16
  17. outbackjackdk

    outbackjackdk n00b

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    Nice build. After your experience with frame failure, have you made any modifications to prevent this in the future? I will be heading rtw in 18 months or so and will be going down those roads so I´d like to prevent it happening. Thanks.
    #17
  18. 2whlin

    2whlin Been here awhile

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    Rad!
    #18
  19. mrwwwhite

    mrwwwhite Been here awhile

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    I would not even think about it. Like I said before my frame fracture is most likely due to a hairline crack after a tarmac crash from the previous owner or a factory problem.
    The occurrence of the second one is very small and it's more likely an error than a bad design. The 690 frame has almost identical design to the one used in the Rally Factory bike so if they don't put them to the test then who is ;)

    :ricky
    #19
  20. spaceman_spiff

    spaceman_spiff Long timer

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    When is the write up getting finished? Super interested to hear all the details!
    #20