KTM 690 Enduro replacement tank bolts – complete subframe reinforcement kit

Discussion in 'Vendors' started by Perun, Feb 15, 2014.

  1. Perun

    Perun Been here awhile

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    LAST EDIT - OCTOBER 25th 2016

    Tank bolt issue explained - http://www.perunmoto.com/blogs/blog/ktm-690-enduro-and-husqvarna-701-tank-bolts-issue-explained


    Link to my web shop - http://www.perunmoto.com/products/ktm-690-subframe-tank-reinforcement-kit

    ------------------------------------

    Below are old and outdated posts, left for reference reasons.

    Everything you need to fix all tank bolts issues (for pre-2014 models and for 2014 model):
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    [​IMG]


    First some common knowledge:
    <o:p></o:p>

    KTM 690 Enduro has known issue with upper tank bolts breaking. On this great model plastic gas tank is actually a subframe, connected to steel tube frame on four spots &#8211; two lower bolts and two upper bolts.

    [​IMG]

    There is a hole all the way through lower section of gas tank.

    [​IMG]

    Lower bolts are going through metal plate bolted to a steel tube frame, and then are bolted to the steel tube that is going all the way through gas tank.
    <o:p></o:p>
    [​IMG]

    As you can see, around steel tube, between the tube and gas tank, are rubber bushings. Those bushings are made of soft rubber and tend to deform easily. When they deform, lower mount is getting unwanted free play. <o:p></o:p>
    Because of that, pressure on upper bolts increase and they break. Upper bolts are not made of material strong enough to bear that additional pressure. In even worse scenario, little metal tab welded to the frame, where upper bolts are bolted to the frame, may crack.


    [​IMG]

    There are few aftermarket solutions available, but none of them solves all issues involved. So, I made my own kit.

    <o:p></o:p>

    So, complete subframe reinforcement kit:
    <o:p></o:p>

    1. Upper parts - upper tank bolt caps and bolts.<o:p></o:p>
    Upper tank bolt caps are made of AISI 4140 steel, then heat treated (for added strength), then zinc coated (rust protection). That makes them virtually indestructible. Size of the head is standard &#8211; 27 mm.There is M6 threaded hole for plastic fairing.

    [​IMG]

    [​IMG]

    Bolts are 10.9 machine bolts, zinc coated. These are much stronger then OEM upper tank bolts. 25mm long, so 1.5mm is in the bolt cap, when mounted on the bike. That is very secure connection.

    [​IMG]

    [​IMG]


    2. Lower parts - lower bushings, steel sleeve, stud, nuts and washers.<o:p></o:p>
    Lower bushings are made of strong plastic, much stronger then OEM rubber lower bushings, yet gentle enough to be in close contact with plastic tank (rubber OEM upper bushings are kept, because completely rigid tank-frame connection wont be a good thing). Slightly different size, so they fit better (really minor differences in size).


    [​IMG]

    Sleeve is made of AISI 304 stainless steel, without internal thread.

    [​IMG]

    Long stud is made of AISI 4140 steel, heat treated (for added strength), then zinc coated (rust protection). Stronger then 10.9 bolts &#8211; very strong. Close fit through sleeve. Part of stud witch goes through steel plate welded to the frame is not threaded so fit is closer - that contributes to strength of this joint.

    [​IMG]

    [​IMG]

    [​IMG]

    Washers are standard stainless steel washers and nuts are standard stainless steel safety nuts.
    <o:p></o:p>
    [​IMG]


    This is everything you need to fix all issues regarding tank bolts. Everything can be installed using standard tools, without advanced technical knowledge, in less then an hour. Including break for beer or coffee. <o:p></o:p>
    Practical, strong design and quality of materials were priorities, not aesthetics. This could look nicer and fancy (different coating), but price would go considerably up. This is not something I do for living, so I don&#8217;t plan to make money out of this, but I do tend to cover all expenses. Here are calculated prices:
    <o:p></o:p>
    Set shipped to USA - 88 USD.<o:p></o:p>
    Set shipped to Europe - 60 Euros.
    <o:p></o:p>
    I am using Serbian post office services, with tracking number. They are good, never lost a package. Yet. Usually it takes 20 days for USA and 15 days for Europe.
    <o:p></o:p>
    PayPal and credit cards accepted.
    <o:p></o:p>
    If interested, please visit www.perunmoto.com


    There is difference between set for pre-2014 models and set for 2014 model. On 2014 model silencer mounts on lower bolt, so longer threaded rod is needed. When ordering, please state what year is your bike.
    #1
    tengri likes this.
  2. Perun

    Perun Been here awhile

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    Instructions and tips:
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    Go for a ride and go low on gas, so gas tank will be as light as possible. Wash your bike.

    <o:p></o:p>
    Install lower parts first. Don&#8217;t dismount upper bolts until you install lower parts.
    <o:p></o:p>
    Before installing new lower bushings and sleeve, use little amount of grease on bushings, inside and outside. Install both lower bushings half way in, then install sleeve. Then install bushings all the way. Tap bushings lightly with plastic hammer, if needed.
    <o:p></o:p>
    Bolt one nut to the stud, all the way. You may bolt both nuts all the way, then unbolt one (either one).

    [​IMG]

    Center all parts accordingly (move tank up and down a bit), don&#8217;t use unnecessary force.
    <o:p></o:p>
    Don&#8217;t over tighten, 10 Nm is enough for lower parts (stud and nuts), and 15 Nm for upper bolt caps and bolts.
    <o:p></o:p>
    When installing upper parts, first install bolts, all the way in (no need to tighten it yet), then install bolt caps (may put few drops of Loctite 243). Move tank up and down a bit, if needed. Then tighten it (yup, 15 Nm).
    <o:p></o:p>
    Install side plastic covers using standard bolts, but add M6 washers (part of the set).

    [​IMG]

    <o:p></o:p>
    <o:p></o:p>
    <o:p></o:p>Note for 2014 models, for lower mounting point: on exhaust side use provided washer AND big stock washer.
    <o:p></o:p>
    <o:p></o:p>

    <o:p></o:p>
    #2
    tengri likes this.
  3. fluff34567

    fluff34567 Long timer

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    PM with order sent :deal
    #3
  4. thumpididump

    thumpididump MacGyver

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    PM sent.
    #4
  5. antoniocadiz

    antoniocadiz n00b

    Joined:
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    PM with order sent


    thanks
    #5
  6. WSobchak

    WSobchak Long timer

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    Good looking kit at a fair price...

    PM inbound!
    #6
  7. Roadie

    Roadie 2-Wheels Rule

    Joined:
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    Nor-Cal
    Waiting for my new bike. Then I will be ready for a 2014 kit.
    Nice work!
    #7
  8. WSobchak

    WSobchak Long timer

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    North Central Washington
    I ordered a set and will post up a review when I get the parts installed.
    #8
  9. Perun

    Perun Been here awhile

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    Belgrade, Serbia
    UPDATE ON PROGRESS:

    Set for 2008-2013. models will be ready for shipping on Thursday, 27. February.

    As for 2014. model:

    I made new, longer threaded rod/stud (actually I made three different versions) and it will be sent to an inmate (Sieg) for final testing. :clap

    If everything goes well, set for 2014. bikes will be ready for shipping in 10 days or so...
    #9
  10. Perun

    Perun Been here awhile

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    Mar 3, 2011
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    Another update:

    New, longer threaded rod/studs (three different versions) will arrive to Sieg for final testing in day or two (maybe three?) :lol3

    Then I will have set for 2014 bikes ready.
    #10
  11. Assfault

    Assfault Exposed Member

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    RockyMountains
    I received my set on Monday, but due to work have not done the install yet.
    Product looks good, and with anything well made, will be a fit and forget type item.
    Thanks Prerun!
    #11
  12. fluff34567

    fluff34567 Long timer

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    I am fitting my kit in the morning and will make a review for interested groups.

    Sent from my GT-I9505 using Tapatalk 2
    #12
  13. WSobchak

    WSobchak Long timer

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    I got my kit in the mail. Looks like good quality stuff. I'll post up a review after I install it as well.
    #13
  14. Perun

    Perun Been here awhile

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    Belgrade, Serbia
    Thank you for comments!

    Thanks to Sieg, who did some testing on his new bike, I know exact measurement of threaded rod for 2014 models. :clap

    So, kit for 2014 model is available!
    #14
  15. sieg

    sieg Wearing out tires......2 at a time, day after day.

    Joined:
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    Yea, Perun sent me some "2014 prototypes" to test, as the lower mount is different than pre-'14. They're nice stuff and he does good work. With my feedback he should be able to make a good fit-up on the 2014's. :thumb

    (And thanks for the free set for my trouble Nikola) :D
    #15
  16. fluff34567

    fluff34567 Long timer

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    I fitted my set today. The bushings are a perfect fit, not too loose and not super tight they have to be forced in. The bushings are a real nice accurate sliding fit. Tiny tap needed for them to go in.

    The middle steel spacer is a nice tight fit thru the bushings also.

    As is the retaining bolt.

    I am very happy with the kit and given the fantastic quality and communication I look forward to any future products from Perun (Nikola).

    Thank you Nikola !

    Sent from my GT-I9505 using Tapatalk 2
    #16
  17. gbx2001

    gbx2001 Geophiz

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    Harperville, Canuckland
    I just read through this thread and was very impressed with both the quality of the replacement tank bolts background and replacement write up, and the machined parts look great too. Excellent work!
    #17
  18. WSobchak

    WSobchak Long timer

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    North Central Washington
    Everything fit but it took awhile to get on my 2008 Enduro.

    Here are some tips and what I did... right or wrong.

    When installing the bottom bolt and bushings I had to loosen the top tank bolts to get enough wiggle room for everything to fit together. Once I figured that out the bottom went pretty smoothly.

    To install the top bolts I had to remove the airbox, which was a first for me. Instructions for airbox removal can be found in the factory service manual.

    When I installed the top bolts and bolt caps the old rubber bushings wouldn't fit because the hole inside the rubber bushings was too small due to the previous owner using the wrong hardware and squishing one of the bushings. I dremeled out the bushing and everything went together fine.

    This is what I mean by "large bolt cap"
    [​IMG]

    I didn't have a socket that would fit the large bolt caps so I used an adjustable wrench until I ran out of room, then I used a set of large pliers. I think it all worked out.

    All together it took me about 2 and a half hours.

    After a short test ride this evening I can say that I am happy with my purchase.
    #18
  19. spaceman_spiff

    spaceman_spiff Long timer

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    What's the next product you're gonna be making for the 690?
    #19
  20. Brown Dog

    Brown Dog North Georgia Dual Sportr

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    :cry
    Get you a set of larger 6pt Metric sockets so you don't ruin these Quality Components :nono
    #20