New and improved KTM690 WUNDERFEST

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

  1. advrider58

    advrider58 Adventurer

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    Mar 21, 2007
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    Good stuff! The wire on my bike has plenty of slack so is under no "pulling" stress. It hangs straight down from the sensor then over to a cable tie at the frame.

    Did you splice in the wire for extra length or as a larger gauge wire to resist a break? :ear

    Mine keeps breaking right at the connector, which is making it very difficult to reuse it.
  2. 690Emaf10

    690Emaf10 Adventurer

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    Apr 9, 2010
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    75
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    Lancaster, pa
    I definitely understand you point. If my pump was priming consistently it would point to something else. When I turn the key on, I heard the pump click but it didn't prime. If I'm in a situation where I can check voltages to the pump it would be a good troubleshooting measure. If those readings are consistent then it merits pointing to the pump. If not, the hunt begins. Hopefully next time I can be prepared to check everything rather than on my way home from work unprepared.

    Now that I've had my first issue it is prudent to be more prepared for an issue. Actually, I should have been prepared from the get go but water under the bridge.
  3. wswartzwel

    wswartzwel Unsafe at any speed

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    Regarding the fuel pump not priming....

    My post wasn't directed solely at you, but at years of posts where the fuel pump is always to blame... I remember when electronic ign. first came out on motorcycles years ago... everyone was replacing CDI boxes whenever there was a problem...




    Being prepared... That is why I carry an extra fuel pump with me on long trips. :D
  4. Albie

    Albie Kool Aid poisoner

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    Longer length, mine had no slack in it and you could see it was always under tension.
  5. SigPig

    SigPig Been here awhile

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    Aug 6, 2012
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    Ottawa
    I have just over 5000 kms on my 2010 690 SMC. The only performance mod was a Wings silencer and an Akra remap which was at around 1500 kms. Everything was working perfectly until I rolled 5k. It's only been ridden on the street with an occasional gravel/dirt road. While I may think I ride it hard sometimes I am most likely not pushing this bike anywhere near it's potential. I've been deployed every summer since I purchased it so it's been in storage more than on the road.

    My 690's fuel pump was failing intermittently and then stopped working all together. When replaced, the new pump fired up and the bike started. During the initialization cycle the bike died after only two minutes of idling. It will no longer start. There is a clicking noise from under the air box somewhere. The fuel pump still hums every time now where as the old one would not turn on at all so that is no longer the issue. It seems to have come up with a new problem now.

    I've been skimming through this thread to find similar issues. Am I correct in assuming that the next thing to check would be the Regulator/Rectifier? Or is there something more simple that I could check next?
  6. Seth S

    Seth S Will _____ for _____

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    sanity?

    No, check the main relay ...right next to the battery. The rectifier wont cause the bike not to start
  7. Uller

    Uller Long timer

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    Not the R/R. That should probably be the last place for you to look.

    You need the Big three. Air, Fuel & Spark

    Check that you are first getting fuel at the fuel injector. Your hose might have come off inside the tank or something simple like that.

    If you are getting fuel.

    Next, see if you are getting a spark by pulling the spark plug and turning it over.

    If both of those are good it becomes harder.
  8. SigPig

    SigPig Been here awhile

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    I will start with those. Thanks guys.
  9. DirtJack

    DirtJack Adventurer

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    I disassembled the plug and used heavier and longer wire, re-crimping and soldering and then sealed the plug and wires with shrink wrap. No problem since.
  10. DirtJack

    DirtJack Adventurer

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    No codes, kick stand eliminator. When the pump doesn't prime, there is no fuel pressure. When it primes it starts and runs great. It has never failed to prime after waiting a variable length of time. My problem is so intermittent (sometimes nearly a thousand miles between occurrences) that I have not yet changed the fuel pump. The only part I've replaced was the filter which was quite dirty. A frustrating problem. Mine has always run like gangbusters just before and after. It has occurred in 100+ and high 30's temperatures.
  11. Xmoto

    Xmoto Death Race

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    Headbutted a tree yesterday.. tree won . Parts is parts.

    [​IMG]
  12. Seth S

    Seth S Will _____ for _____

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    Been there done that. Trail tech was kind enough to sell me a new light frame for a reasonable price
  13. Barman

    Barman Way Offline

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    :cry
    You could put the stock mask back on while you're waiting for parts.
    Should be in with the spare bits that went with the bike. :evil
  14. Xmoto

    Xmoto Death Race

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    Ordered new light frame from trail tech, the p/n in 3832-00-frame if anyone needs it.
  15. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    I agree with your assessment that vibration on an unsupported wire is the culprit. It is poor engineering to allow a wire to exit, unsupported, via a sharp-cornered hole. That will cause the wire to fatigue and break 100% of the time over the long run.

    The solution is to add a stress relief rubber. It doesn't have to be anything fancy like a factory-made part. It can be a long, skinny cone of RTV or Shoe Goo (i.e. some type of goop that sets rubbery, not hard... i.e. no JB Weld!) that is built up from the connector outward to the wire. Make it the full diameter of the connector -at- the connector, and about 1" long, tapering down to the wire size. Just something that makes it impossible to kink the wire as it flexes.

    a

  16. blakrj

    blakrj Need to ride

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    Also check all earths are good. If coil earth is bad, starter will turn over and you'll have no hint of ignition. Checking relay a good place to start if you keep hearing a clicking sound
  17. DirtJack

    DirtJack Adventurer

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    The fuel pump prime issue I have is likely not a grounding issue as the bike has always cranked strongly. It will not start without the fuel pump prime. No point even trying to start it without the prime; just runs down the battery. As soon as you can hear the fuel pump prime sequence, however, the bike always starts and runs normally.
  18. jonnykilo

    jonnykilo Traveller

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    Oct 25, 2006
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    East Coast Canada
    Thanks Gez. I have the engine out, and am going to see what a dealer has to say - in the meantime, gotta move tomorrow so this ass-pain with the Katoom will have to wait.

    jak
  19. advrider58

    advrider58 Adventurer

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    Mar 21, 2007
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    Location:
    El Paso de Robles, CA
    Good advice. Thanks all! As of last night, it's fixed.

    Rather than re-soldering to the "stub" wire exiting the connector, I took the connector completely apart this time right down to pulling the pins from the plug. I removed the stock wires and replaced them with eight inch leads of 14 gauge that I soldered to the pins. No relying on crimp connections. After reassembling the connector, I soldered the leads into the wire harness. Both leads are packaged together into shrink wrap from the connector to the wire harness, and I added a second outer layer of shrink wrap enclosing the wires and the entire end of the connector at the exit point.

    Hopefully I've got it all covered now. Larger gauge wires, strain relief and enough mass to resist any vibration fatigue. All the wires are also zip tied to the frame rails with just enough slack for a natural unstressed bend.

    I still would like to replace the connector (it's well worn now from all the wire replacements and rework), so if anyone finds a replacement source, please share.

    Thanks again--let's ride!!

  20. Michelangelo

    Michelangelo 2 wheel rider...anytime..

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    Can someone recommend a rear shock collar spanner wrench for the 2008 690E? I bought an Enduro Engineering one (for sale in Flea Market for $25) that turned out to be only for the single collar shocks. I'm told I need a hinged one to work on the 690's shock. Any recommendations?