New and improved KTM690 WUNDERFEST

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

  1. ktmmitch

    ktmmitch Been here awhile

    Joined:
    Sep 29, 2009
    Oddometer:
    725
    Location:
    uk
    The 690 sidecar is nearly complete in the fab shop at Abbotts Farbrication,and all the works is nearly done.An new airbox was fabricated to hold the UniFilter and the battery,the exhaust header was routed to the silencer and a mesh guard fitted,the car size radiator was mounted along with the header tank,and a neat VMC rad protector was water-jet cut from 3mm aluminium sheet to finish the whole thing off.
    Next on the list is to complete the wiring harness connections,and get ready for the MOT test to get it road-legal.
    [​IMG][​IMG]
  2. motoged

    motoged Been here awhile

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    Feb 26, 2006
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    908
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    Kamloops, BC
  3. ABuck99

    ABuck99 0.0

    Joined:
    Feb 21, 2009
    Oddometer:
    633
    Location:
    Georgia
    SG-

    Nice write up & vid- and cool work space you have there - we'd like to check out some of those other bikes in the stable sometime.

  4. Sutherngintelmen

    Sutherngintelmen around the bend

    Joined:
    Mar 12, 2009
    Oddometer:
    1,216
    Location:
    ATL
    I spent the week earning parts money in Sioux Falls SD. Nice town, fun people, good eats and drinks. They go big for Xmas - light show is downtown, surrounding the falls. Back last night, just before today. Thank you for the lots of good ideas, haven't tried any of them yet. Not a fan of shopping but after yesterday's fn mess at Sandy Hook, walking around anywhere with my 12 year old sounded lucky.

    Sioux Falls SD cell photo - it's beyond the lights.

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    Could well be - it's a great lead. Have been reading alongat's thread from back in August with evening cocktail.

    Digress - if you like such things, I highly recommend Herradura Reposado, fresh squeezed lime, Reed's ginger beer on rocks garnish with JalapeƱo. :1drink

    May indulge on your offer to lend a temp test swap r/r; going to be making slow progress for the next few weeks with travel and such. It appears an easy change, may be one of the parts I replace regardless as it seems known and prone.

    btw - thanks for the book rec on John Boyd You ffs who like fighter pilots, unsung heroes, game changing strategic thinkers or brash ball busters might enjoy this too: "Why die all tensed up?"

    Nice :thumb I can try that one eazy :D I swapped oem thermo for the 88c switch Quick to know if it's an issue, may be eating just enough amps to hook me.

    I'm just going to order the CA pump right :pynd peace of mind plus r&r is such a gas. :lol3 Thanks for the FI read - good stuff. I think I'm going to to rig up a pressure test on current pump. Bob or Crank wrote up some ideas a few pages back. Be interesting anyway. Maybe I'll get a geyser like the spilt filter show. :eek1


    Not going to rule that out - haven't checked the valves. I did the fan switch swap too, kicks in quick. Spent an August week in Montreal and can assure you that generally it's warmer down here :nod Cuz is a jazz drum major at McGill - will be skiing CA with him week after next.:wings Fantastic town (and country) you have there.

    Thanks, I'm ok with words and pics it's fix that don't come ez:shog Workspace has some sweat in it. City living gots its goods but land ain't one. Propped up under the party deck on my hill. Been meaning to take some pics and post in the bike shed thread.

    Other bikes is good news ifn you're a 690 owner:freaky The only one in there that doesn't have a fix list is the Duc. :lol3

    ABuck edit: just proofreading and noted you're an airhead. :augie I'm posting sos there too - got some R80gspd improves in action. Spokes with drum is a toaser lwb '73 June build beauty.

    [​IMG]
  5. crankshaft

    crankshaft Guns are for pussies

    Joined:
    Aug 12, 2004
    Oddometer:
    14,005
    Location:
    Burlingtron,VT
    Do any of you guys have the Euro rear fender part number, the one KTM Twins sells with the LED tail light? My dealer sent the wrong fender and I'm trying to get it worked out. THX
  6. KC-10ENG

    KC-10ENG Been here awhile

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    Aug 19, 2010
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    115
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    Las Vegas, NV
  7. Biped

    Biped NooB Again

    Joined:
    Jul 8, 2008
    Oddometer:
    360
    Location:
    Oregon, Wet Side
    From my archive, what I bought, fit without issues. No license plate light though, not that I care.

    Part: 76508016000
    Unit Price: $22.72
    Requested Quantity: 1
    Comment: NUMBER PLATE CARRIER TOP 08 for KTM
    --------------------------------------------------------------------------------
    Part: 76514040000
    Unit Price: $61.65
    Requested Quantity: 1
    Comment: REAR LIGHT for KTM
  8. modeselector

    modeselector Common as muck

    Joined:
    Jul 2, 2009
    Oddometer:
    624
    Location:
    Washington USA
    Here you go (google it to be sure):

    76508016000 - top black carrier
    76514040000 - led tail light
  9. blakrj

    blakrj Need to ride

    Joined:
    Aug 16, 2009
    Oddometer:
    191
    Location:
    Cloggland via Borneo, TX, UK, Oz and S.Africa
    Crank, you can find a full EU chassis spare parts manual here.
  10. crankshaft

    crankshaft Guns are for pussies

    Joined:
    Aug 12, 2004
    Oddometer:
    14,005
    Location:
    Burlingtron,VT
    Thanks folks! I sent the number to my dealer and he sent me the stock US version:lol3
  11. Sutherngintelmen

    Sutherngintelmen around the bend

    Joined:
    Mar 12, 2009
    Oddometer:
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    Location:
    ATL
    I tried a couple of ideas this afternoon - no fix but eliminating potentials is progress - right? :lol3

    I went after the fan switch & r/r ideas because no parts required. Hooked up a volts meter to monitor flow thinking maybe an electrics drop could be root of things. Don't think so based on tests.

    Here is the cold start of 15 minute idle reset. Bike doesn't get to stalling even when temps go up. Fan did kick on during 15 minutes which seemed a good indicator not electrics related and unlikely valves - speak up, but bike shouldn't idle smoothly until I kill it if purely heat driven issue would arrive with temp.

    Battery at rest >13v, drops to 12.4 during ecu boot then up to 14 at idle.

    <iframe width="560" height="315" src="http://www.youtube.com/embed/Ak3gv9DjLRg?rel=0" frameborder="0" allowfullscreen></iframe>

    Here the bike has been running 15 mins without so much as sniff let alone a cough or stall. Rectifier is pretty hot but I can touch it without burns, maybe five seconds before it's uncomfortable. Plastics were off but no breeze. Volts still > 14.

    <iframe width="560" height="315" src="http://www.youtube.com/embed/BOJQjIAQZhU?rel=0" frameborder="0" allowfullscreen></iframe>

    Shut off the bike, then try to restart after a couple of minutes. In this case the fan switch was plugged in.

    <iframe width="560" height="315" src="http://www.youtube.com/embed/mj-rdPfZx9Q?rel=0" frameborder="0" allowfullscreen></iframe>

    A few seconds later with fan switch unplugged - no difference.

    <iframe width="560" height="315" src="http://www.youtube.com/embed/9psNmwwAk_k?rel=0" frameborder="0" allowfullscreen></iframe>
  12. blakrj

    blakrj Need to ride

    Joined:
    Aug 16, 2009
    Oddometer:
    191
    Location:
    Cloggland via Borneo, TX, UK, Oz and S.Africa
    I'm sure you mentioned that you'd checked the earth, but just in case. I had odd behaviour, bike ran great when cold, but when it warmed up, coughed spluttered and eventually would not restart. While waiting for a pickup, fiddling around and noticed that when pressing bracket for my regulator (relocated for RR tanks) it would fire up. Tow truck arrived and I asked for some tools to remove, clean and tighten bracket. Fired right back up and I was on my way. Sorted for months until a big Euro trip. After fuel stop on day 1, bike started its coughing, spluttering and died. Stripped tanks, cleaned up frame and off I went again, only to have it happen again shortly. Repeated this 2 more times with the same ultimate result. Dead bike! So, it looked to be more than a poor earth on the frame. What it did turn out to be was the coil mount/earth, which is on the same bracket. I cleaned up the metal on the coil (where the bolts go through) and ran an earth lead (luckily had brought some electrical cable in my spares) from the coil earth direct to the neg on the battery. Has been that way since July and been without issue. Your regulator looks okay as voltage is not spiking (at least what I can see). Shouldn't go above 15V at 5k RPM. All that being said, Rod on the Sibersky Extreme ride also had odd issues and it turned out to be his fuel pump. KTM engineers have also suggested to check the TPS as a possible cause. Hope you get it sorted.
  13. ini88

    ini88 Been here awhile

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    Aug 26, 2009
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    New York, NY
    Luke - fishfind had a problem with his rectifier on this trip from South Africa up to England. Have you tried replacing or borrowing a spare rectifier to see if that is the problem? His seems to die out randomly too but while riding.
  14. Bill the Bong

    Bill the Bong Supern00ba

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    Dec 20, 2006
    Oddometer:
    1,015
    Location:
    Kalahari South Africa
    Since he reports issues at a certain temparature cut-off, I would focus next on items that is known to malfunction when heating up - coil and regulator.

    Not helping much, sorry.
  15. ktmmitch

    ktmmitch Been here awhile

    Joined:
    Sep 29, 2009
    Oddometer:
    725
    Location:
    uk
    We have designed a replacement solid front disc,300mm,to suit the KTM 690 Enduro which has a hole to accept the KTM EXC magnet & circlip,to line up with the M8 tapped hole in the caliper mount.
    This will enable an ICO to be used without having to drill the existing floating disc,or glue a magnet on.


    We also have a rear disc designed to offer as a straight replacement for the OEM item.


    These are expected to be available by end January.


    Another spin-off is they will fit KTM 950/990 Adventure models,all 690 & 450 Rallye.






    [​IMG]
  16. MrHix

    MrHix Been here awhile

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    Mar 16, 2012
    Oddometer:
    384
    Location:
    MO
    Will it work with the 2012 690 Enduro R with the flat sensor on the fork caliper holder?

    Cheers,

    MrHix
  17. toast

    toast Been here awhile

    Joined:
    Nov 18, 2006
    Oddometer:
    243
    Location:
    San Fernando Valley, CA
    My fuel line connector pictured below is broken and KTM is back-ordered until Dec 28.
    This is the connector under the seat that allows you to take the sub frame off and provide you the convenience of a quick disconnect of the fuel line.
    Do any of you fine inmates have this part you can sell me?
    I also heard some people swap the factory plastic stuff for some quality brass fittings, but I can't seem to find that posting.
    Any help is appreciated.

    Toast

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    Ride on!
    [​IMG]
  18. Albie

    Albie Kool Aid poisoner

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    Mar 31, 2004
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  19. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

    Joined:
    May 8, 2006
    Oddometer:
    3,043
    Location:
    Louisiana, Baton Rouge
    Toast- It's a NAPA 10 micron filter (finer filtration than stock) # 3095, and they're metal.

    This thing has been on my list now for a few months.

    Make sure to get hose clamps suitable for high pressure fuel injection systems.

    Dirty
  20. ktmmitch

    ktmmitch Been here awhile

    Joined:
    Sep 29, 2009
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    725
    Location:
    uk
    It will fit,but the flat sensor for the speedo is not activated by a magnet,but from the 6 disc screws.The hole is for a KTM EXC magnet to work with an ICO,or similar.