KTM 690 Adventure (re)build

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

  1. 640 Armageddon

    640 Armageddon Xplorer

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    It's coming up nicely mrwwwhite,

    Pardon my ignorance (I have a 640 after all :D ) , about the rocker arm failures. Is that the bearings we are talking about, or the whole thing.
    If my memory serves me right, they changed it with a better part. Is'nt that so?

    Quick question.
    I see the brackets are of specific thickness. Sheet bending them means a specific radius of bend, for SS usually equals the thickness of the material, for Aluminium it can vary so that the material does not 'tear'. I see in the brackets, multiple radii. Is that how they are actually manufactured?
    How does the aluminium look on the outside? There were rumours, I think it happened to Poskitt as well, that the OEM RFR exhaust brackets are prone to cracking and I was wondering the reason. May be they are too thin for the job, were yours look beefy. One way to get a little away is to peen then afterwards. This will give them some more life fatigue-wise.

    Looking forward to seeing the build, I got a new RFR seat in the garage... Looking ways to improve it :patch
  2. mrwwwhite

    mrwwwhite Been here awhile

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    It's a bearing issue. Sometimes after the bearing fries (rollers are gone) it can break the arm that holds the bearing pin but that is clearly a consequence. They changed the PN in 2012 and everybody was raving about finally the "new" design solved this issue but after few months people reported failures with the "new" design as well. The difference is in the way the bearing pin is peened in place.

    That different radius slipped while modeling... You got me there :p. Actually the radius in real life was smaller that what I designed (4mm inside 7mm outside) more like 2-3mm inside and 5-6mm outside. It worked ok and there were no signs of fatigue from the cold forming.

    The bracket Lyndon broke was the middle one, close to the peg area. It was more due to poor design IMHO. It was just a triangular bracket welded on the pipe generator. A loop bracket would be more suited and probably last longer.
  3. joenuclear

    joenuclear Long timer

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    [cross posted] I wonder if the rocker arm failures have anything to do with Zinc being removed from motor oil? There have been a lot of cam shaft failures reported on vintage engines due to this.
  4. Kookz

    Kookz Adventurer

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    I hope your wrist is recovering well. Don't overdo it just because it feels ok! I pulled a pair of pins out of my thumb a few years ago and thought the bone was healed, only to break it 3 days later. Another surgery, 7 screws, a plate and I've got a thumb with very limited mobility. Heal up!

    Are you planning to sell a kit to mount the fairing and tanks? If so...highly interested. Excellent work!
  5. sebyno

    sebyno Adventurer

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    Hope you get well soon.
    High interest also for me.
  6. mrwwwhite

    mrwwwhite Been here awhile

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    I really cannot tell. All I know my f@#$ed intake rocker arm bearing looked like an unlubricated, fried mess.
    More on, yesterday a friend whom I managed to convince to pull the trigger and swap his DRZ on a '08 690 came in Bucharest and I upgraded his newly acquired bike (EVO1 map, UNI filter, deSAS, rad protector, fork rebuild and revalve). I also checked the rockers and imagine... on the intake side the rocker shaft was installed in the wrong position (holes and marker facing down). The bike has 12.000km and I doubt anyone messed with this after the engine was assembled in the factory.

    Cheers Kookz! That sounds like a nightmare. On the same note a distant friend broke his hand few years ago, had surgery with plate, bolts & the whole mess, and then two weeks later he went back to the hospital to have his wires removed. Guess the luck, on the stairs he fell and broke his hand again so he had to go back into surgery and have everything repaired, again.

    Guys really thank you for all the get well wishes! It means a lot!

    For those interested, YES there will be a kit available after I finish the prototype and have everything planned up. I really wish to have all my ideas, experience and sweat I've put into this project (and I'm not yet finished so more sweat coming up) transformed into the most advanced/good looking kit available for the 690 (and I'm not the only one who wants that).




    With the help of my friend I payed a visit to my welder bud. He still never finished the middle footrest exhaust mount and tried to convince me that from his experience such a mount is prone to crack because of the metal expanding under extreme heat. Well... I'll have to make something by myself and prove him wrong ;). Riding the bike back home was awesome and my wrist felt right on the slowish tared road. Boy I've missed the braaap in this one and a half month since my crash. Guess who showed up at the hospital for recovery this morning dressed up with riding gear. :hide

    Luckily my recovery doctor is also a biker so he totally got it. He even loved the looks of my rally bike and was impressed with my work. :)

    Here's few from this morning 15' reset (new exhaust).

    [​IMG]


    [​IMG]
    640 Armageddon likes this.
  7. Kookz

    Kookz Adventurer

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    How are you liking the attachment for the tower, using the Sikaflex?
  8. mrwwwhite

    mrwwwhite Been here awhile

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    Hey Kookz, the tower is attached to the frame using a head bracket I designed.
    Besides the upper bolted tabs (that connects with the ignition switch bracket like most other kits out there) because of it's geometry it interlocks itself on the head stem.
    From experience and from other riders reports I come to understand that in time, because of vibration the slightest free play in this mount will have pretty damaging consequences (most of the failures of the brackets start from this).
    I guess it's hard to beat the RFR welded tabs for simplicity and durability.

    "Sikaflex" is if you want what Lock-tight is for a bolt. It just prevents the free play of the head mount to occur in time.

    Here's a render of the mount.

    ImageUploadedByTapatalk1439182852.121700.jpg
    640 Armageddon likes this.
  9. bigborett

    bigborett Hipster

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    Great thread and look forward to finished result. Maybe a must have for my 690. Your work is fantastic.
    Feel for you with wrist, just had shoulder surgery 2 days ago myself.
    640 Armageddon and mrwwwhite like this.
  10. mattadv93

    mattadv93 Been here awhile

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  11. ErÑete

    ErÑete Been here awhile

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    Perfect fairings sells! We expect to see the result! It would be the bike of my dreams!
  12. MAXVERT

    MAXVERT Fiddling while Rome burns

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    (For those interested, YES there will be a kit available after I finish the prototype and have everything planned up. I really wish to have all my ideas, experience and sweat I've put into this project (and I'm not yet finished so more sweat coming up) transformed into the most advanced/good looking kit available for the 690 (and I'm not the only one who wants that).

    I think you'll find that the PF fiberglass kit will need considerably more work from the buyer to end up with a complete nicely detailed bike.

    It looks like mrwwwhite will have a fully bolt on kit, complete with pipe and skid plate.
    Hopefully at an affordable price ( Quest not ).
    I'm sure we will see more updates soon.
    I plan to put one on my 2014.
    Also if you have not looked through this whole thread, he's built a beautiful carbon
    air box, which maybe he'll sell too.
    Max
    Renaissanceman likes this.
  13. 640 Armageddon

    640 Armageddon Xplorer

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    As Yoda said, 'Patience you must have my young padawan' :D
  14. ErÑete

    ErÑete Been here awhile

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    you're going to sell the kit? I thought it was the perfect fairings!
  15. mrwwwhite

    mrwwwhite Been here awhile

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    Cheers mate and speedy recovery for your shoulder as well!


    Hey Matt, so far we only saw teasers as they called them. I've had the same parts back in february and it's easy to take some pretty photos, use parts from other bikes and yell "a new kit is coming!", but it's a long way to have it finished and ready for production. Since at least in my case the main components are from the Factory bike (and not copy of them) the most crucial aspect is to make them fit and last on the 690 frame which is not an easy thing to do if your focus is quality and durability.

    Yes, Perfect Fairings only sells... no designs, no tests, nothing. Feel free to go that way but your result will be far from a dream and it very possible that will turn into a nightmare.

    Cheers Max! 640 Armageddon quote is just perfect :)!

    As for the PF fiberglass work, I would also add that fiberglass fuel tanks are a pretty dangerous thing to play with. Yes it's used for racing, but that is full CF and reinforced Aramid with very special and expensive epoxy resins and fuel resistant coatings. They are used for one season and then no one risk to have their bike on fire. Besides that we are talking about big teams with hefty budgets which is not the case for PF.

    Spot on D.!

    Hey ErÑete, I'm not in any way affiliated with Perfect Fairings and in fact I consider their work mediocre to say the least. Personally I would never use any of their parts not to mention the so called kits.
    PeterKaa likes this.
  16. mrwwwhite

    mrwwwhite Been here awhile

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    Ok enough with that and let's move to some more interesting information.
    A while back I was posting some infos regarding a lower temperature fan switch. The information was wrong and in fact the M14x1.5 thread is for the smaller enduros in the KTM lineup.

    The 690 uses a M18x1,5 thread for the thermoswitch and I just found an automotive perfect match with the same thread and same plug. At 93dgC I think is just cooler enough (OEM KTM is 102dgC).

    Here's a photo and you can see the matching models. Probably following the models but with different engines other temperatures can be found.

    Price for the one in the picture.... 12Euro :)

    or you can get this: http://www.rally-raidproducts.co.uk...erformance-upgrades/thermostat-switch-ktm-690


    [​IMG]
  17. Mikemm

    Mikemm Long timer

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    I also am suspicious of how durable and safe a fiberglass tank is. Ive seen claims, but I dont trust it.

    One thing I noticed is how many of their kits dont show their brackets... and you end up with this amateur looking piece http://www.perfect-fairings.com/assets/media/DSCN3920.JPG
  18. MAXVERT

    MAXVERT Fiddling while Rome burns

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    ^^^ I feel the same, that's why I'm waiting (Yoda like) for this 450 kit.

    I've actually had PF offer their new kit to me if I do a bike build and write up.

    Max
  19. sebyno

    sebyno Adventurer

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    Also me.
  20. sebyno

    sebyno Adventurer

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