New and improved KTM690 WUNDERFEST

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

  1. Bill the Bong

    Bill the Bong Supern00ba

    Joined:
    Dec 20, 2006
    Oddometer:
    1,032
    Location:
    Kalahari South Africa
  2. TheMuffinMan

    TheMuffinMan Forest Ranger Magnet

    Joined:
    Mar 31, 2010
    Oddometer:
    6,553
    Location:
    Denver, USA
    So I did the first valve check on my 2012 enduro with 624 miles on the clock. Fired right up, but there seemed to be more valve noise than usual, bike ran fine, warmed up. Changed the oil and the noise didn't subside. Took the skid plate off and it was still noisy.

    My 950 has somewhat noisy valves, and my v-strom was noisy too. The 690 is the same noise but louder to the point where I'm a little worried (though it's a new bike so I'm kind of nit-picky :lol3). Tore it down to the valves again and everything was at .13mm except one exhaust was .14mm . The bike had the same level of noisy valves after about 550 miles but they were all tight when I checked them and reshimmed them to .13mm but the noise persists.

    I know these bikes are noisy but I looked more closely and saw some scoring marks on the rocker arm bearings, perhaps these marks are normal, and the noise is normal?

    Here's a picture:
    [​IMG]
    Larger Picture
  3. tattewell

    tattewell Mad Poser

    Joined:
    Mar 16, 2009
    Oddometer:
    802
    Location:
    Petawawa Ontario
    Im not sure if they fixed the rocker bearings, but mine let go on my 09 and ate the top end. If in doubt, swap em out!
  4. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,445
    Location:
    On a RTW ride - next stop USA!
    Here you go, their stuff is normally very good quality as they only work with top manufacturers like CP etc.

    http://www.gw-racing-parts.de/index2.php?view=tuning&HID=21&type=690&von=2006&bis=2010&lan=en

    Tuningkits

    KTM 690 (2006-2010)

    <table style="margin-left: 17px;" border="0" cellpadding="0" cellspacing="3" width="658"><tbody><tr style="background-color: #BEC1C0; height: 20px;"> <td width="79">Product-Nr.</td> <td width="149">Product</td> <td width="254">Description</td> <td width="114">Picture</td> <td style="text-align: center;" width="59">Retail &#8364;
    (without tax)</td></tr><tr class="edit"><td style="vertical-align: top;">KTM690/06-09/ST1</td><td style="vertical-align: top;">Tuning-Kit 1</td><td style="vertical-align: top;">Tuningkit KTM690 stage 1. New Camshaft Stage 2. CP forged pistonkit of the extra class 102 mm. Compression 11,8 : 1. Delivery including the suitable piston rings, wrist pins and wire locks. Inclusive cylinder honing with diamond honing stones. Cylinder honing is necessary concerning the correct running clearance and the surface roughness adequately to the piston ring.</td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">536,43</td></tr><tr class="edit_gray"><td style="vertical-align: top;">KTM690/06-09/ST2</td><td style="vertical-align: top;">Tuning-Kit 2</td><td style="vertical-align: top;">Tuningkit KTM690 stage 2. New Camshaft Stage 2. CP forged pistonkit of the extra class 102 mm. Compression 11,8 : 1. Delivery including the suitable piston rings, wrist pins and wire locks. Inclusive cylinder honing with diamond honing stones. Cylinder honing is necessary concerning the correct running clearance and the surface roughness adequately to the piston ring. Cylinder head porting inclusive radius valve seat cutting. Inclusive shot peen of the combustion chamber and channels.</td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">665,71</td></tr><tr class="edit"><td style="vertical-align: top;">KTM690/06-09/ST3</td><td style="vertical-align: top;">Tuning-Kit 3</td><td style="vertical-align: top;">Tuningkit KTM690 stage 3. New Camshaft Stage 2. CP forged pistonkit of the extra class 102 mm. Compression 11,8 : 1. Delivery including the suitable piston rings, wrist pins and wire locks. Inclusive cylinder honing with diamond honing stones. Cylinder honing is necessary concerning the correct running clearance and the surface roughness adequately to the piston ring. Cylinder head porting inclusive radius valve seat cutting. Inclusive shot peen of the combustion chamber and channels. Including crankshaft balancing.</td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">789,86</td></tr><tr class="edit_gray"><td style="vertical-align: top;">KTM690/06-09/ST4</td><td style="vertical-align: top;">Tuning-Kit 4</td><td style="vertical-align: top;">KTM 690 bigbore - tuningkit. New camshaft stage 2. Cylinder boring for 104 mm and new LFC plating. CP forged pistonkit of the extra class 104,00 mm, + 2 mm oversize, compression 12,5 : 1. Delivery including the suitable piston rings, wrist pins and wire locks.Cylinder head porting inclusive radius valve seat cutting. Inclusive shot peen of the combustion chamber and channels. Including crankshaft balancing.</td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">1090,47</td></tr><tr class="edit"><td style="vertical-align: top;">NKTM690/06-10/ST2 </td><td style="vertical-align: top;">Camshaft</td><td style="vertical-align: top;">New camshaft stage 2! More top end power ! Very good for bigbore engines.</td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">292,86</td></tr><tr class="edit_gray"><td style="vertical-align: top;">PCPKTM690/06-09/102m</td><td style="vertical-align: top;">Piston</td><td style="vertical-align: top;">CP pistonkit of the extra class 102,03 mm. Compression 11,8:1. The cylinder must be honed with diamond honing stones. Cylinder honing is necessary due to the fact that the piston especially for the overhaul has a slightly oversize of 0,03 mm.</td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">220,00</td></tr><tr class="edit"><td style="vertical-align: top;">PCPKTM690/06-09/104m</td><td style="vertical-align: top;">Piston</td><td style="vertical-align: top;">CP - Forged Pistonkit of the extra class 104,00 mm, + 2 mm oversize, compression: 12,5 : 1,. Delivery including the suitable piston - rings, wrist pins and wire locks. The cylinder must be bored for oversize and new coated. </td><td style="text-align: center; vertical-align: top;">[​IMG]</td><td style="vertical-align: top; text-align: right;">220,00</td></tr><tr class="edit_gray"><td style="vertical-align: top;">KTM690-HSC3</td><td style="vertical-align: top;">Piston coating</td><td style="vertical-align: top;">HSC3 piston coating </td><td style="text-align: center; vertical-align: top;">
    </td><td style="vertical-align: top; text-align: right;">40,86</td></tr></tbody></table>
  5. blakrj

    blakrj Need to ride

    Joined:
    Aug 16, 2009
    Oddometer:
    191
    Location:
    Cloggland via Borneo, TX, UK, Oz and S.Africa
    Did you not gt a parts manual with your new '12 bike?
  6. ABuck99

    ABuck99 0.0

    Joined:
    Feb 21, 2009
    Oddometer:
    665
    Location:
    Georgia
  7. TheMuffinMan

    TheMuffinMan Forest Ranger Magnet

    Joined:
    Mar 31, 2010
    Oddometer:
    6,553
    Location:
    Denver, USA
    They don't make a short oil filter for the 2012 yet (the design changed).


    I didn't get a parts manual; I bought the bike used, from a guy (even though it only had 220 miles or so on it). All it came with was an owners manual.
  8. ABuck99

    ABuck99 0.0

    Joined:
    Feb 21, 2009
    Oddometer:
    665
    Location:
    Georgia
    sorry for that- Hiflo has it wrong

    here you go

    KTM PN: 75038046100 OIL FILTER SHORT

    http://partsfinder.onlinemicrofiche...ke=ktmdb&a=570&b=44&c=0&d=-LUBRICATING-SYSTEM
  9. Seth S

    Seth S Will _____ for _____

    Joined:
    Jul 19, 2004
    Oddometer:
    4,841
    Location:
    sanity?

    It should also be noted that HiFlo makes the filters for KTM and KTM then puts their stamp on them and doubles the price :rofl
  10. Kirkster

    Kirkster Parts Murderer

    Joined:
    Dec 1, 2011
    Oddometer:
    296
    Location:
    Peoples Republic of MD
    Anyone??? Anyone???
  11. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,146
    Location:
    Some were in , lostralia
    No the plugs are different but the wiring maybe the same you might be able to do s plug swap
    It will be a fiddly pia job .
  12. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
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    Location:
    Some were in , lostralia
    Oh you will have no taco if you do the swap
  13. thorinoakenshield

    thorinoakenshield ya mo be there

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    Dec 22, 2011
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  14. RoninMoto

    RoninMoto Wanderer

    Joined:
    May 12, 2010
    Oddometer:
    1,706
    Location:
    In the mountains?
    I just cleaned mine out a few weeks ago. Turned out one of the pins for the LCD was broken so I had to solder. I can also recommend using some di-electric grease on the pins for the LCD. This will help the crappy connection.

    I can post pics if you want.
  15. LethPhaos

    LethPhaos brb

    Joined:
    Aug 16, 2012
    Oddometer:
    618
    Location:
    Belgistan
    I need to do a valve check, I understand how to do it but I'm not sure about the TDC part, does anyone have info/pictures on how to do that?
  16. Albie

    Albie Kool Aid poisoner

    Joined:
    Mar 31, 2004
    Oddometer:
    10,202
    Location:
    NWA
    There's a timing mark on the camshaft, you'll see it when you are looking down on it right by the timing chain gear. Also, the holes will line up that allow you to remove the rocker arm shafts when you're at TDC.
  17. RoninMoto

    RoninMoto Wanderer

    Joined:
    May 12, 2010
    Oddometer:
    1,706
    Location:
    In the mountains?
    There are 3 holes in the cam shaft gear. You turn the crank shaft CCW until the center hole is about at the 8mm bolt that holds the cam shaft in. Shine a light through this hole, there is a small line on the cam shaft and a small line on the camshaft retainer. When they line up, you are at TDC. Sorry I don't have a pic.
  18. Albie

    Albie Kool Aid poisoner

    Joined:
    Mar 31, 2004
    Oddometer:
    10,202
    Location:
    NWA
    Here's a pic of the timing mark:

    [​IMG]

    And the hole alignment

    [​IMG]
  19. KTM-RIDER4LIFE

    KTM-RIDER4LIFE Born to ride

    Joined:
    Dec 14, 2012
    Oddometer:
    4
    Location:
    Gaybec, or better known as Quebec
    Nice picture of the upside down wreak on the beach!
  20. Seth S

    Seth S Will _____ for _____

    Joined:
    Jul 19, 2004
    Oddometer:
    4,841
    Location:
    sanity?
    There is TDCF and TDCE... you will want to line up the crank mark as well...as you want TDCF---firing...all valves closed.