New and improved KTM690 WUNDERFEST

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

  1. thorinoakenshield

    thorinoakenshield ya mo be there

    Joined:
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    Cool!
    I'll be riding around Ocala, Appalachicola, and Osceola National Forest on Sunday March 10 --> March 12.
    If anybody wants to meet up. I was able to get some gpx tracks, too, from a nice Floridian.
    Here's my trip planning thread:
    http://www.advrider.com/forums/showthread.php?t=849397

  2. dad2bike

    dad2bike Retired! Cranky Old Fart

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    FINALLY MADE IT!
    :clap:clap

    It took me 3 weeks to get thru all 466 pages of this thread. :eek1

    My Ginger has been sitting on a stand waiting for me to give her some attention. :lol3

    I've gleaned about 5 written pages of items to be inspected on my bike as well as a bunch of links to videos and posts on mods and fixes. Great information from a great bunch of people!

    I've got a big mountain of goodies to be installed.
    One more weekend of distraction (Parker 425) and then I can start to get cozy with Ginger. :evil
    I sure hope my Big Orange doesn't get jealous. Maybe I should ride her to work since it is warming up. :D
  3. Baja Dad

    Baja Dad Long timer

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    I will call you later in the week.
    I may be coming out to Parker on friday.
  4. dad2bike

    dad2bike Retired! Cranky Old Fart

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    This sounds expensive for me. :huh :lol3





    I still have not seen a direct answer about if the 690 swing arm requires water drain holes like the EXC & adventure swing arms. :ear
  5. Albie

    Albie Kool Aid poisoner

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    I'm sure it wouldn't hurt to go ahead and drill the holes. Heck, I've never bothered to drill my EXC. I just slather on some anti seize on the adjuster bolts every now and then.:lol3
  6. TheMuffinMan

    TheMuffinMan Forest Ranger Magnet

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    So rocker arm bearing play. What exactly is to be tested? I want to know personally but since this is one of the main known issues with the bike it'd be great to put a blurb up on the wiki about it as well.
  7. Albie

    Albie Kool Aid poisoner

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    From what I understand it's abnormal wear and scoring.
  8. meteorite

    meteorite MoreDust

    Joined:
    Oct 25, 2009
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    36
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    Panama SA
    Took my 09 Enduro R for a spin on the nearby beach today. Noticed a momentarily sputter earlier at full throttle 3rd gear. Not too worried then as she kept going good after that. Later, as distance between home and more fun grew, one more sputter and silence:super:. For the first time since I had my bike I got a FI code. Boy was I exited !!! 3 long 7 short= ignition coil issues. Ok time for payback after all the fun I had. Due to location and some other considerations, I started the long push home:kurt. Great review on my Sidi boots to follow. Made it home late (or early I should say) bit thirsty:slurp but in good spirit. Tomorrow I shall tackle the issue:bubba. Quick read in my repair manual says to check resistance between two indicated points on the coil:deal. Thats where I'll start. If anyone here dealt with similar issue, any advice/recommendations/findings will be liked.:asta
  9. Head2Wind

    Head2Wind MotorcycleMayhem

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    mine did this to me out in the middle of no where this past summer.... part of this was my fault for not making sure that the coil wires were completely onto the terminals on the coil while doing PM, service and reconfig of systems. The first portion of it showed up on the trail in the midst of a 4 day ride. I managed to find it, and "fix" it, or so I thought.... I turned round on the single track that we were on and headed back out 2 miles to the road and then we rode access roads to meet up with the rest of the Epic Dual sport riders.... and 3 blocks away from the hotel right after a traffic light, engine off like a switch.. and FI codes 3-7, which at the time ment bumpkis to me on the side of the road in 105 deg F Wenatchee. I figured that there was something else wrong and so I pushed the bike to the hotel, again, still in 105 deg F. After several LARGE beers at the restaurant one of my riding buddies who is the parts manager at the local KTM store said "hey, I found the manual for my 350 online, can't find the 690, but it says that 3S-7L is a coil fault".... So we had a direction to go in to solve it... We went back to the hotel parking lot and I tore into it, pulling the right side rally tank off and the regulator so I could get to the coil without issue (coil relocated for rally tanks) and there you have it.... F'n wire had completely fallen off the coil. So I pulled the other wire off the coil and preloaded the connectors (squeezed with pliers) and made damn sure that they both went completely onto the coil terminals. Started right up, no hiccups since and its been through some fun trails for sure!:deal
  10. meteorite

    meteorite MoreDust

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    Thanks H2W. Shall check that for sure. Wouldn't be surprised if I have the same. Good fun though. Way to meet people:freaky. The locals had a good giggle as they squeaked by on old rusty bicycles and unpronounceable brand motorcycles.:rofl
  11. KC-10ENG

    KC-10ENG Been here awhile

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    I wish I didn't have to post this here but another radiator bites the dust! My day started out bad but ended well after the radiator was repaired and topped off! The test ride after the repair was 109 miles of double and single track followed up with 35 miles of slab.

    [​IMG]
  12. Seth S

    Seth S Will _____ for _____

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    sanity?
    So its fixed again? My radiator was bent around a tree...got fixed and os still on the bike
  13. Albie

    Albie Kool Aid poisoner

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    I'm on my 3rd radiator and I never hit shit. :lol3
  14. Seth S

    Seth S Will _____ for _____

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    Send them to mylers he will fix. Remove the top fan shroud bolts and zip tie instead
  15. Yellow Pig

    Yellow Pig Allergic to asphalt!

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    Here is a picture from RoninMoto's (Noah) bike:

    [​IMG]

    You can really see the abnormal wear on the roller.

    Some comments made on the roller by Gunnerbuck:

    Hi Noah,
    It is not common for the valve clearance to loosen and this usually points to other issues... Normal operation and valve wear will drop the valves farther into their seats and thus reducing the clearances to the tappets...

    Usually on the 640 and 690 when the clearances open it means that actual cam follower roller needles are on their way out and have developed slop... When it is run closer to the point of failing the cam follower bearing may quit turning altogether and gall up the camshaft lobe... With a keen ear you can usually notice a change to the tappet noise and how it emits a louder klikety klak before it does any damage... The next time you have the rollers exposed try giving them a wiggle to see if there is slop...

    A couple of videos:

    http://www.youtube.com/watch?v=MBwmIaa0PDk

    http://www.youtube.com/watch?v=wtwCl_yGa-Y
  16. Albie

    Albie Kool Aid poisoner

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    I gave them back to KTM when they warrantied them. Fixed the fan shroud problem after the first failure. The first replacement rad just spontaneously sprung a leak 2 weeks after it was installed. The second replacement rad sprung a spontaneous leak as well last summer, but I just JB welded that fucker. :lol3
  17. dad2bike

    dad2bike Retired! Cranky Old Fart

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    Is there already a 690 Oil thread? I'll just open up the can of worms in here?
    Im using the same oil in my Diesel, Honda cars, RFS bikes & 950A. All with good experience. Long time between changes & higher fuel mileage
    It is Synthetic rated at 5W-40.

    How critical is the heavier weight for the 690? I see 10W-60 & 10W-50 listed. What keeps me from using the 5W-40?

    :ear














    :hide
  18. Albie

    Albie Kool Aid poisoner

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    Sounds about right, my valves always went to the tight spec. I replaced my rocker arms just because I noticed a little bit of catching when I spun the bearings. Figured since I was replacing everything else in the valve train while I was doing the top end, I may as well replace those.
  19. Yellow Pig

    Yellow Pig Allergic to asphalt!

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    How critical is the heavier weight for the 690? I see 10W-60 & 10W-50 listed. What keeps me from using the 5W-40?



    I've heard that it's because of the silver bearings that 10W60 is required:

    Note that there's some indication that KTM has used silver bearings in the new LC4 motor. Using silver, instead of lead, provides greater strength than any other bearing material, and it also resists corrosion better and is more thermally conductive. Silver bearings are more typically found in heavy duty marine diesels or jet engines. Unfortunately, the detergents in automotive and motorcycle motor oils (primarily ZDDP) will attack and eventually degrade silver unless they are specially stabilized. This may be the reason behind KTM's strong endorsement of the Motorex Cross Power 4T 10W-60."<!-- google_ad_section_end -->

    I'm not sure I really understand why10W60 & silver bearings are connected, but that's what KTM claims.

    Some KTM forums thought that the oil was low detergent, low ZDDP, or otherwise stabilized to work with silver-plated bearings.

    Here is an interesting oil analysis of the 10W60 that KTM reccomends:
    http://www.bobistheoilguy.com/forums/ubbthreads.php?ubb=showflat&Number=1189269#Post1189269







    Brand New Motorex 1-W60 Analysis:

    [​IMG]


    Right out of the bottle it doesn't measure as a 60-weight; it looks more like a 15W-50, actually.
  20. dad2bike

    dad2bike Retired! Cranky Old Fart

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