New and improved KTM690 WUNDERFEST

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

  1. Oz-Strom

    Oz-Strom Still trying

    Joined:
    Mar 17, 2005
    Oddometer:
    787
    Location:
    Brisbane Australia
    Good outcome. As crank says above - replace the internal fuel filter with an external one. I fitted mine inline after the quick-connect. So much easier to swap out whenever you feel like it :D
  2. Brute

    Brute Melbourne , outer east .

    Joined:
    Dec 6, 2007
    Oddometer:
    1,073
    Over a year ago my 08 690 on occasions would stall & be a bit hard to restart . I replaced the fuel filter & fitted 1 of those screen filters to the top of the injector. I noticed the old fuel filter was full of black crap . First ride with the new filters I travelled about 100 kays & the bike would barely run . I removed the small screen filter from the injector & it was full of tiny black particles . I left the injector filter out & the bike ran ok again but I still had occasional stalling issues & the bike started to feel a bit doughy in the power department . In other words no improvement . The fuel pump always primed whenever the ignition was turned on . The bike seemed to get more doughy over time till it felt gutless . I pulled out the injector & back flushed it . Tiny little bits of black crap came out . Refitted the injector & went for a test ride . The bike felt a lot better for 20 minutes then went gutless again , reflushed the injector & more tiny bits of black crap came out .Refitted went for another test ride , went ok for 20 minutes , bike stops & wouldn`t restart . Got the bike home , back flushed injector again , more tiny bits of black crumbly stuff came out , refitted injector & bike still wouldn`t go . Turned out to be a fouled plug . On close examination of the plug I could see the spark arcing across to tiny small bits on the porcelain near the centre electrode . I then bought a fuel pressure gauge & tested . Only 25 psi pressure . I pulled the pump out & tested it in a bucket in case a hose was kinked or something . Still only 25 psi . I also noticed the recently fitted in tank fuel filter was again full of black crap . I replaced the fuel pump with a C.A. pump , replaced the injector & filter & refitted the little gauze filter to the top of the injector . The bike goes like a rocket again & hasn`t missed a beat for the last 5000km .
    I have no doubt the black crap in the filter , injector & on the plug were bits of the brushes from the fuel pump .I know these tiny bits were getting through the standard tank filter over time & blocking the injector ( & tiny injector filter ) The original pump always primed & never needed a tap to get going yet in the end it would only pump half required pressure .
    Note : When back flushing the injector I aimed it into a clean white tray & used a magnifying glass too see the black particles .
  3. Buzztail

    Buzztail NMBBMFBK

    Joined:
    Sep 30, 2007
    Oddometer:
    11,003
    Location:
    BUZZTOPIA
    Just a side note. You don't need to build a fancy 9 volt battery thingy to cycle the injector you HAVE a very expensive injector cycler sitting in the garage, and it happens to be in an area where you're already working.
  4. rickypanecatyl

    rickypanecatyl SE Asia adventure tours

    Joined:
    Jan 21, 2008
    Oddometer:
    1,190
    Location:
    Kuala Lumpur, Malaysia
    Gotta link to that video?
  5. RoninMoto

    RoninMoto Wanderer

    Joined:
    May 12, 2010
    Oddometer:
    1,706
    Location:
    In the mountains?
  6. Albie

    Albie Kool Aid poisoner

    Joined:
    Mar 31, 2004
    Oddometer:
    10,187
    Location:
    NWA
    I'm beginning to think that modern motor oil doesn't really smoke much when it burns. I know when my valve seals went out on my V Strom I had no clue I was burning oil. No smoke at all, but it burned up 3 qts in 1K miles.
  7. RoninMoto

    RoninMoto Wanderer

    Joined:
    May 12, 2010
    Oddometer:
    1,706
    Location:
    In the mountains?
    You might be right. Would explain a lot.
  8. MeinMotorrad

    MeinMotorrad Long timer

    Joined:
    Sep 21, 2012
    Oddometer:
    1,697
    Location:
    UK for now.
    I went through 300ml in a 500 mile, day long trip, on on a Honda 125 scooter - no smoke, no leaks, no clues - still don't know where it all went. The oil capacity was only 850ml.
  9. bobzilla

    bobzilla Dirty Old Man

    Joined:
    Apr 19, 2006
    Oddometer:
    937
    Location:
    Lost & Found again in the Great Basin
    singles in particular vent a good deal of oil at high rpm.s
  10. blakrj

    blakrj Need to ride

    Joined:
    Aug 16, 2009
    Oddometer:
    191
    Location:
    Cloggland via Borneo, TX, UK, Oz and S.Africa
    Thankfully I've been lucky in that department. Recent 5,600km ride with some very long blacktop stretches and high speed. Didn't have any noticable oil loss. Bike now has 17k kms on the clock. Maybe my unsympathetic break in did it some good.
  11. Barman

    Barman Way Offline

    Joined:
    Apr 16, 2011
    Oddometer:
    1,166
    Location:
    Saratoga Springs, NY
    Yup, big single cylinder, high compression. Check the airbox and you guys will see where at least some of the missing oil is going. :deal
  12. Albie

    Albie Kool Aid poisoner

    Joined:
    Mar 31, 2004
    Oddometer:
    10,187
    Location:
    NWA
    Heck, I'm amazed at the fact mines never used oil considering that I ring the crap out of it. It spends so much time at red line it's not even funny. I'm not surprised at all I'm doing a valve and ring job at 27K miles though. :lol3
  13. Harty

    Harty Bloody Good Bloke!

    Joined:
    Mar 29, 2010
    Oddometer:
    267
    Location:
    Devon, UK
    Anyone got a good link for a supplier of Mapping Switch that I can mount on my bars for my 2011 690E. Am UK based as well. :wink:

    Cheers
  14. Night Crawler

    Night Crawler Been here awhile

    Joined:
    Mar 14, 2012
    Oddometer:
    119
    Location:
    Portland, OR
  15. Harty

    Harty Bloody Good Bloke!

    Joined:
    Mar 29, 2010
    Oddometer:
    267
    Location:
    Devon, UK
    Thanking you sir, you're a star :clap
  16. MFS

    MFS Been here awhile

    Joined:
    Apr 2, 2009
    Oddometer:
    230
    Location:
    Prairies...
    Swapped out the Tank Fuel filter, with the Napa 3011. Stock filter was dark? But I didn't see any alien particles in there. New filter in, took the injector off and cycled the bike on and off to clear the fuel line into a bucket. Cleaned the injector again, hooked er all up and the bike started up instantly. But stalled again...

    Haven't ran a pressure test on the pump, will have to pick up a gauge (thanks again for the tip Crankshaft). No one has a sparkplug in town, so will order one tommorrow, and probably just order a Cycleworks pump and drop that in. If it doesn't improve anything, well heck I got a spare pump then. If it fixes it then I'm good to go!

    Bike ran at idle for 5 minutes or so, then died. Started right back up easy enough, would idle, then die. TIre is still off it so I didn't try ridin. If I can't get it running perfect in the garage no sense trying to flog it down the road I figure...

    Was so intimidated at first by working on the fuel system, but it really is simple on the 690 I'm finding? Provided the pump fixes it and it gets runnin of course...no one within 3 hours who could remap it for me either. Suppose I could check the pressure, first, and if its working try to remap, incase its off for some reason.

    Will sleep on it,:deal ride safe y'all!

    MFS
  17. bobzilla

    bobzilla Dirty Old Man

    Joined:
    Apr 19, 2006
    Oddometer:
    937
    Location:
    Lost & Found again in the Great Basin
    ^^^^^^^^^^^^^^^^^^^
    check the TPS?
    after you check pump pressure and plug
  18. MFS

    MFS Been here awhile

    Joined:
    Apr 2, 2009
    Oddometer:
    230
    Location:
    Prairies...
    Referring to turning the electrical on and rolling the throttle on and off? Or a different check...

    I'll search online before I head to work here and see...

    MFS
  19. bobzilla

    bobzilla Dirty Old Man

    Joined:
    Apr 19, 2006
    Oddometer:
    937
    Location:
    Lost & Found again in the Great Basin
    check the voltage readings and adjust. need tune ecu or the dealer.
  20. MFS

    MFS Been here awhile

    Joined:
    Apr 2, 2009
    Oddometer:
    230
    Location:
    Prairies...
    Phhaaa AACKKKK!! That's kinda what I'm readin and finding out. Nearest dealer 3 hours, and "the guy" to talk to didn't return my call yesterday, and it was recommended I don't leave a message but call back as he is a busy guy :huh

    Will try him again of course but my crystal ball tells me it's a 6 hour round trip, and a stalling issue when I get home! :rofl

    The "tuneECU hardeware is downloadable, any idea where to get the required cable in Canada? I'll have to look more in depth look after work, and see how that's all done. Might as well do it all myself and eliminate the middle guy! Sucks for them though...

    Idled for 6 minutes this morning though, like a loved one comin out of a trance. We spoke, she told me she loved me, I touched her and looked in her pretty orange face as she slipped away from me again...

    And when she was gone I swore at her and called her an ignorant C__t!:D

    MFS