New and improved KTM690 WUNDERFEST

Discussion in 'Thumpers' started by crankshaft, Sep 6, 2011.

  1. CanadianX

    CanadianX Oh!? That is deep.

    Joined:
    Dec 26, 2010
    Oddometer:
    1,815
    Location:
    Ontario
    Mine seems to run hot as well, hotter than my friends 2011 for sure. In slow traffic temp will rise quickly to the point where the fan kicks in but even on hot days on tight trails it has never run up into the last two bars. I may change the coolant to see if I can cool the bike a bit with a bit more water in the mix. Also check you coolant level, I was surprised to see the bottom hose connection on the overflow tank has a slow weeping leak, it being a brand new bike and all. I did have the bike back fire and stall in the heat once. Likely this is also when my TB started to work loose, a lean condition in the heat I guess. I've since added a FMF pipe and Akro map. No more back firing and TB hasn't moved since.
  2. jared1843

    jared1843 Drifter

    Joined:
    Jun 2, 2009
    Oddometer:
    144
    Location:
    Ponchatoula, LA
    2011 has an orange frame... As the ktm gods intended.
  3. DirtJack

    DirtJack Adventurer

    Joined:
    Aug 12, 2007
    Oddometer:
    1,609
    Location:
    San Antonio, Texas
    Another way is to pull both inserts out, drill the holes all the way through and then use longer bolts bottom up through the holes and hold them in by pulling the inserts (use a suitable locktite) back into position leaving studs to hold the air box cover (RR filter, etc) with nuts.
  4. DirtJack

    DirtJack Adventurer

    Joined:
    Aug 12, 2007
    Oddometer:
    1,609
    Location:
    San Antonio, Texas
    I had the same problem and I completely disassembled the plug and was able (it took a long time) to even un-crimp each connector and then re-assemble with new wire (longer) and covered the whole assembly with individual shrink covered by a shrink over both wires. My recollection was that the hardest part was inserting the new wires through the waterproof connector because the wire I had on hand had a slightly larger OD. It is doable if you work slowly with a bit of patience.
  5. BCC283

    BCC283 n00b

    Joined:
    May 13, 2012
    Oddometer:
    6
    Location:
    Big Cottonwood SLC
    I just purchased an new '11 690 after much research (most of which was on here) and have been 2 for 2 on rides so far, i.e. couldn't make it back half the time. 350 on the odo and will stall and or not start when warmed up. I'm thinking maybe the fuel pump as I can only hear a "click" when I turn the key, but I really have no idea. I just came up on 5 days off and was going to go for a good ride, but as the bike is now at the dealers I decided to head to MX and rot on the beach. :dutch
    Anyone else having these problems?
  6. Night Falcon

    Night Falcon Adventure NZL

    Joined:
    Dec 25, 2008
    Oddometer:
    2,501
    Location:
    New Zealand
    I think its just vibration fatigue but managed to fix it ok. Have put some pictures of fix on my 690 thread but heres the finished job

    [​IMG]
  7. dirtbikeslob

    dirtbikeslob Been here awhile

    Joined:
    May 4, 2007
    Oddometer:
    300
    Location:
    dunedin new zealand
    :thumb:thumb
  8. MookieBlaylock

    MookieBlaylock Long timer

    Joined:
    Feb 29, 2004
    Oddometer:
    2,581
    Location:
    IntheeaglewingpalaceoftheQueenChinee
    i was going to just remove and replace the overflow tank because of this but for the life of me could not figure out how to pull it out of the frame, so i painted it up with rtv
  9. snakepilot

    snakepilot Adventurer

    Joined:
    Mar 9, 2006
    Oddometer:
    65
    Location:
    Lake Murray, SC
    I have performed the above procedure, including installing a Renazco billet filler neck and an in-line one way valve to the scavenge fuel hose. My problem is that I am building pressure inside the tank (fuel vapors normal expansion).
    I thought the one way valve would stop the denser fuel from escaping, while allowing some air to exit to accommodate fuel vapors and ,of course, allowing air to come in to fill tank as fuel is depleted. Do I need a different valve, or should I just vent the hose to atmosphere without any valve?

    I would appreciate a comment from those that have performed this modification.

    TIA,

    John
  10. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    Aug 5, 2007
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    1,717
    Location:
    Oakland, CA
    I'm sensing a trend that Mookie is fond of RTV. :rofl
  11. Barman

    Barman Way Offline

    Joined:
    Apr 16, 2011
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    1,166
    Location:
    Saratoga Springs, NY
    I installed the Renazco neck as well but with no valve. I eliminated the evap canister so just cut the hose to the correct length after running it down by the right side of the shock.
    I was fueling one day and when I removed the gas cap I noticed a vacuum had built in the tank. Removed the seat to see what was amiss (it's just a rubber line wtf could be the issue? :huh). The seat bumper that rests on top of the battery hold down was pinching the vent line. Moved the line and zip tied it out of the way.
    Gotta give credit to the fuel system on the 690, not even a hiccup out of the engine with a vacuum in the tank. :deal
  12. Evil Invader

    Evil Invader Been here awhile

    Joined:
    May 22, 2006
    Oddometer:
    700
    Location:
    Hell-sing-land, Sweden
    Well that´s a first! :eek1

    :lol3
  13. Barman

    Barman Way Offline

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    Apr 16, 2011
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    Saratoga Springs, NY
    Gotta throw the dog a bone occasionally. :rofl
  14. snakepilot

    snakepilot Adventurer

    Joined:
    Mar 9, 2006
    Oddometer:
    65
    Location:
    Lake Murray, SC
    Barman,
    I appreciate your reply. In your case, the pinched fuel line was the culprit. I do not have any "kinks" on the line, but following the procedures on Bartron's "code orange" thread to do a partial canirestomy and installing the one way valve has not worked as advertised.
    I know that lot's of inmates have done this modification, so my question is: have you just vented to the atmosphere as Barman did, or did you use a one way valve? If you did, how is it working out?
  15. SnapCracklePop

    SnapCracklePop Re-Noobified

    Joined:
    Jan 5, 2006
    Oddometer:
    7
    Location:
    Sutter Creek, CA

    I've been just running the vent to the atmosphere ... been like this for more than 3 years now with zero problems.
    I just don't trust those 1-way valves.

    [​IMG]
  16. Night Falcon

    Night Falcon Adventure NZL

    Joined:
    Dec 25, 2008
    Oddometer:
    2,501
    Location:
    New Zealand
    I use a valve on my safari tank. I have had problems in the past on particularly dusty rides when it has become blocked and starved the engine of fuel. It was simple enough to unblock by removing, tapping on the handle bars and sucking some air through. Its been pretty reliable otherwise. They recommend atleast 1 inch of vent hose between the pertrol cap and the valve for them to work....maybe thats your problem?
  17. Brute

    Brute Melbourne , outer east .

    Joined:
    Dec 6, 2007
    Oddometer:
    1,067
    I suspect those 1 way valves lock up when the fuel & vapours expand , ie leave your bike sitting in the sun .
  18. CanadianX

    CanadianX Oh!? That is deep.

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    Dec 26, 2010
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    1,815
    Location:
    Ontario
    Pretty much the plan. I was hoping with a few heat cycles the rubber grommet thing would expand and seal properly. Now on to plan B - rvt :D
  19. Albie

    Albie Kool Aid poisoner

    Joined:
    Mar 31, 2004
    Oddometer:
    10,029
    Location:
    NWA
    Probably the culprit. Both times I've had one lock up it's been riding out in some serious heat. I just stopped using the things and went back to regular hose.
  20. nippybit

    nippybit Nippybit

    Joined:
    May 31, 2010
    Oddometer:
    92
    Location:
    Henderson, Nevada
    John,

    I have a full cannisterectomy on my 2010 R and I also have the Renazco filler neck and Acerbis cap. I am assuming here that you also have an Acerbis screw-on cap. If so the cap has a center vent recessed into it. I just use a no-slop short hose valve (about 2 1/2 inches high) which allows the tank to breathe but prevents excess fuel from escaping. The no slop valve just mounts vertically into the cap recess and onto the male vent. I have the factory vent hose, which is connected to nothing at either end, just tucked under the seat. No vacuum problems with my tank and I routinely fill it to its maximum capacity, i.e., 3.2 gallons.

    Hope this helps.

    P.S. No problems with gas tank venting in almost three years, with the bike left in the sun (in Southern Nevada summers), in the shade, etc. Got a good quality no-slop valve at Cycle Gear and it has never failed.