KTM 690 Adventure (re)build

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

  1. mrwwwhite

    mrwwwhite Been here awhile

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    :freaky Not much progress since my last post but hopefully by the end of next week I'll have the moulds ready and the alu parts cut.
    #81
  2. spaceman_spiff

    spaceman_spiff Long timer

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    Are you building up your 690 with rally tanks and what not or gonna keep it mostly as is? Or is that the big secret ending?
    #82
  3. mrwwwhite

    mrwwwhite Been here awhile

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    Stick around and you'll find out, and this answer is not for the above questions ;) and ask OC to bring some beer. :))))
    #83
  4. VxZeroKnots

    VxZeroKnots Long timer

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    It's cool I'm patient.
    #84
  5. spaceman_spiff

    spaceman_spiff Long timer

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    Oh boy!
    #85
  6. mrwwwhite

    mrwwwhite Been here awhile

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    It all starts with some big boxes. :p

    ImageUploadedByTapatalk1429302612.833366.jpg
    #86
  7. spaceman_spiff

    spaceman_spiff Long timer

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    Did you order direct from ktm?
    #87
  8. DesertRatliff

    DesertRatliff Tinker Tinker Ride Ride

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    Just read that post by OC! Didn't realize RR might be part of the plan. :clap:lurk
    #88
  9. LukasM

    LukasM Long timer

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    Excellent work as usual, mrwwwhite. :clap

    I had to reinforce the front of my factory rally airbox because it had a hole from rubbing on the frame (not sure why, maybe because I have a 450 RFR frame on my 690 RFR), so it is a bit longer now. This means that the mounting holes don't quite line up and it's under tension when I use them and touching in the front. I've therefore put some rubber tubing on the front frame crossmember and left the airbox itself loose except for the rear boot attachment. No issues over >20k kms through some rough terrain, with the added benefit of being able to access the top end by unclipping the seat and loosening a single hose clamp.

    I'd still incorporate the rubber isolators in front and back so that the box is a bit wedged in but would leave the front bolts out and just use the rear ones that you can access without taking the front tanks off (assuming you are going to fit some).
    #89
  10. mrwwwhite

    mrwwwhite Been here awhile

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    Guys I promise an update this weekend!

    Thanks for the feedback Lukas, watch out for Asian ladies and crazy backpackers. It looks like after the remoteness of Central Asia and Siberia you enjoy the easygoing of SE Asia.

    Even from the “drawing board” stage, one of my design requirement was to be able to access the injector without getting both tanks out. Both is out of the question since the clamp on the throttle body is covered by the tanks, but after your input it’s clear that one is achievable.

    Since my design incorporates the velocity stack on the airbox you gain even more rigidity so I’m thinking only a second mount through silent blocks to the frame airbox mount tabs in the front. This mount should be made in two pieces connected using bolts that can be accessed from above or why not one dzus. This way the airbox can be taken off only with the right tank off (which doesn't have the fuel pump in it so only gravity feed the system). Pretty nit!
    #90
  11. Dotbond

    Dotbond Africa, Africa

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    Are you going to make a direct replacement for the standard airbox as well? :wink:

    Mine is leaking around the thermoweld join at the top.
    #91
  12. mrwwwhite

    mrwwwhite Been here awhile

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    It should clear the stock seat without any problem so I don't see a reason why this airbox could not fit a stock 690 as well.
    #92
  13. LukasM

    LukasM Long timer

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    Yeah SE Asia has been great, rode some awesome offroad trails in Laos and Cambodia thanks to inmate Justin aka team_FTB who hooked me up, and of course I have enjoyed meeting some nice tourist ladies as well. :wink:

    I would look how you position the rear airbox clamp, maybe you can access it without even taking one tank off? I can on the Rally by aiming the 6mm bolt head facing right and up.

    By the way, another tip that we found out the hard way - the open design of the Rally air filter means that water can very easily enter from the front if you go through deep-ish water too fast so that it creates a big bow wave. Some sort of splash shield that fits around the front of the air filter and directs the water to the side instead of up and into the filter would help a lot..
    #93
  14. mrwwwhite

    mrwwwhite Been here awhile

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    Thanks for both tips. As the airbox is pretty slim in the TB area is very plausible that following your suggestion to be able to take it out without getting the tank out. That would be pretty awesome.
    A splash guard would be good. Maybe a welded Alu sheet on the one that is bolted I the airbox would do the trick. Also I tried to keep the angle of the air filter facing backwards for the same reason. I know that on the rally airbox the filter is tilted forward which increase the chances of water ingress.


    I know I promised a major update this weekend but I've spent the time learning how to use a lathe :) and I made those bits.
    I know now everybody is moving to CNC as the price of such machinery is slowly dropping but there's something so cool in this old machine and I ve always been attracted to them but never got the chance to use it.

    ImageUploadedByTapatalk1429533443.488419.jpg

    On the left I made the mounting bolts and spacers for the rally filter, center bits are for the tank mounts, left some tower spacers and in the back is the spacer for the old LC4 rear wheel to match the front SX in my second moussed enduro wheel set.
    #94
  15. mrwwwhite

    mrwwwhite Been here awhile

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    Thanks Ulller! For the oem airbox your idea is pretty awesome. Since mine will be shorter and slimmer I think I can make a bracket in the front without cutting the frame tabs. ;)
    Glad to share my passion for the 690 with this community since is my source of inspiration anyway.
    Sorry or not posting more often but the project itself it's pretty time consuming so not posting is actually a good thing cause it means I'm doing some progress :).

    ImageUploadedByTapatalk1429604281.769884.jpg

    More parts ready.
    #95
  16. mrwwwhite

    mrwwwhite Been here awhile

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    ImageUploadedByTapatalk1429604342.639816.jpg

    This one is work in progress but by noon I'll have a billet rear tank cap and adaptor. No more fuel on my brand new white rear plastic when I enjoy this wheely machine :)
    BTW all Alu parts are made from a super tough 6082 T6 alloy later probably anodized black.
    #96
  17. mrwwwhite

    mrwwwhite Been here awhile

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    Done!

    ImageUploadedByTapatalk1429625580.374527.jpg
    #97
  18. spaceman_spiff

    spaceman_spiff Long timer

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    Dang
    #98
  19. bob66

    bob66 Been here awhile

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    I didn't know why I was always feeling some gas smell from my tank...

    So this thing fixes this?

    Cristian / Bob
    #99
  20. mrwwwhite

    mrwwwhite Been here awhile

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    Totally! I used it already for two days now and no more fuel spill. Next I'll laser cut a Alu sheet to fill the triangle shaped area then off to a black anodizing for a nice black stealth look.