New and improved KTM690 WUNDERFEST

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

  1. Night Falcon

    Night Falcon TRIUMPH TIGER 800XC

    Joined:
    Dec 25, 2008
    Oddometer:
    5,192
    Location:
    New Zealand
    I had a similar problem on my Beta's air box. Not an easy fix but I managed to drill the nut out and silicone a new one in using industrial grade silicone. There was a heap of plastic around the nut so didn't make a hole getting it out. It will be a lot harder on the 690 tank though.

    Noticed a while back how these bolts are susceptible to rusting being upside down with no where for moisture to drain out. I now remove them regularly clean and grease them. :wink:

    Good luck with getting it sorted Ged :nod
  2. lightfighter

    lightfighter where does this go?

    Joined:
    Dec 23, 2007
    Oddometer:
    2,303
    Location:
    Sierra Vista AZ.
    dont do this till someone else wieghs in, cuz im spitballing here, based on my airbox threaded insert coming loose on the 09 i dont have anymore....

    its spinning right? spin it and heat up the plastic. pull out the threaded insert. put that in a vise, drill the remnants of bolt out, chase the threads with the appropriate tap to clean it up, then put it back into the hole with some epoxy. use a new bolt and no more that say 10nm of torque.
  3. bobzilla

    bobzilla Dirty Old Man

    Joined:
    Apr 19, 2006
    Oddometer:
    1,093
    Location:
    Lost & Found again in the Great Basin
    its a tough one.. i had one come loose and I used epoxy carefully to add girth to the nut. when I did get it out i always used anti sieze on all the bolts that are in plastic
  4. DuctTape

    DuctTape Been here awhile

    Joined:
    Sep 12, 2011
    Oddometer:
    351
    Location:
    Kansas
    Here's a better pic of my 990 with the Flexx bars and all the switches installed I use for my lights, heated gear, etc and access isn't a problem.

    [​IMG]
  5. Uller

    Uller Long timer

    Joined:
    Jun 18, 2008
    Oddometer:
    1,737
    Location:
    Arlington, WA
    This is how I have solved this problem in the past. Not on the 690 tank but, on the 950 tank and a snowmobile tank.

    Might add.....make sure you don't push in while it is hot. Always spin it while pulling at the same time if possible. Be sure to clean both surfaces very well prior to epoxy. To reinsert grease up a bolt to hold onto, the grease is so any extra epoxy doesn't lock it in too, I always use liberal amount of anti-seize on all insert type bolts now days.
  6. chrislitt

    chrislitt B-KTM-W

    Joined:
    Aug 15, 2011
    Oddometer:
    94
    Location:
    Stockton, CA
    Thanks for the tip but we don't have those guys out here. Probably can't afford California; getting harder all the time for all us. Found some on ebay and I'm not in a hurry- well, life won't let me be in a hurry on this project. I did get to go on a Fathers Day dirt bike ride today with my younger son in the Sierras. Best gift a dad could have, roaring around all day in a rock garden and tight trails with his son! Love my 300XC-W. Woops, 690 thread. Flames no doubt coming. :eek1
  7. alpine rider

    alpine rider Adventurer

    Joined:
    Aug 5, 2006
    Oddometer:
    30
    Location:
    Silverton Colorado
    Hmmmm, not the answer I was hoping to hear. Are you saying the light is marginal compared to the BD LED? That I believe....but if yer saying it's marginal compared to the stocker, then I'll keep looking.

    Seems like we've got several options if one is willing to shell out 4-500 bucks. I was hoping to keep it on the cheap.

    Is the X2 halogen offroad any better? I'm not going down the road of HID. If I have to spend the $$ it'll be an LED
  8. AccelRus MaxiMus

    AccelRus MaxiMus Been here awhile

    Joined:
    Apr 27, 2013
    Oddometer:
    207
    Thanks - better angle for sure.

    As per Baja Dad, now I understand
    why they use the extra mount bolts
    to beef up the top clamps - for the
    handguard mounts...

    All makes sense now - looks like a
    bomber set up

    Slick dual locking caps on the 990 - you
    get those done custom, or ?
  9. v8toilet

    v8toilet Nothing to see here.

    Joined:
    Jul 11, 2005
    Oddometer:
    1,738
    Location:
    Northwest U.S.
    Those are stock fuel caps on the Adv.
  10. Oz-Strom

    Oz-Strom Still trying

    Joined:
    Mar 17, 2005
    Oddometer:
    820
    Location:
    Brisbane Australia
    Just wondering - I have a 2011 Aprilia Shiver 750 Sport and these (and many other FI bikes) are renowned for twitchy/jerky throttle at constant revs in the 3-4000rpm range. The best solution appears to be a Fat Duc adjustable variable resistor pot inline with the O2 plug on the exhaust. I have installed this cheap device and it works wonders - now smooth as. I don't really understand the FI - O2 thingy, but on the Aprilia it gets around the lousy OEM mapping that is used to pass emissions tests.

    Would such a like device be any use on the 690?

    some more info here http://www.apriliaforum.com/forums/showthread.php?271442-Made-my-own-FatDuc-the-ChunkyDorso
  11. Oz-Strom

    Oz-Strom Still trying

    Joined:
    Mar 17, 2005
    Oddometer:
    820
    Location:
    Brisbane Australia
    Noticed on the weekend ride that the digital clock on the dash (08 690E) twice reset itself to 12:00. There doesn't appear to be a battery power issue as it starts and runs fine. Maybe a dash connector issue?

    Anyone with ideas or similar problem?

    Thanks
  12. Night Falcon

    Night Falcon TRIUMPH TIGER 800XC

    Joined:
    Dec 25, 2008
    Oddometer:
    5,192
    Location:
    New Zealand
    does any one know a fix for disappearing digital speedo numbers? My speedo has just started loosing its digits and this is the replacement 990 version changed under warranty...the quality of these speedos is really way below par KTM :ddog
  13. motoged

    motoged Been here awhile

    Joined:
    Feb 26, 2006
    Oddometer:
    911
    Location:
    Kamloops, BC
    OZ-S,
    I have had that problem with my '96 BMW 1100GS since new....some wrenches were able to reduce the surging in that rpm range, but recent BMW shop "tuned" it and it is surging and bucking more than ever....back to the shop for a third time....wonder if that would work for the GS?

    Thanks for the tip :deal :clap

    Ged


  14. SKINNY

    SKINNY Been here awhile

    Joined:
    Jul 23, 2001
    Oddometer:
    775
    Location:
    West Texas
    check the plug on the backside of the instrument panel...it may have worked loose...
  15. Seth S

    Seth S Will _____ for _____

    Joined:
    Jul 19, 2004
    Oddometer:
    5,070
    Location:
    sanity?
    :scratch
  16. modeselector

    modeselector Common as muck

    Joined:
    Jul 2, 2009
    Oddometer:
    687
    Location:
    Washington USA
    That cable can be finicky but my experience is that if that cable is not seated properly, the tach/spedo won't work either.
  17. Bill the Bong

    Bill the Bong Supern00ba

    Joined:
    Dec 20, 2006
    Oddometer:
    1,278
    Location:
    Kalahari South Africa
    Yes, had an 1150 like that. It was related to Throttle Body set-up, but the surging was at steady throttle openings. Incidently, they also had a jumper that could richen it up (even though it was supposed to be used for lower octane fuel)
  18. sennenhund

    sennenhund n00b

    Joined:
    Mar 29, 2010
    Oddometer:
    1
    Location:
    Mammoth Lakes, CA or Santa Barbara, CA
    Hi all, with 5000 miles on the bike a starter issue has arisen. It appears not to be the battery (as it is charged) but starter attempts to turn over a few times then stops and you can hear an audible clicking sound.

    Any thoughts?

    Thanks
  19. Velociraptor

    Velociraptor TrackBum

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    Apr 17, 2005
    Oddometer:
    1,426
    Location:
    Seattle
    If all else fails check the ground wires that bolt to the frame near the upper right bolt for the gas tank. One of those wires broke and my speedo lost all the digits. There are a bunch of wires that all are connected to ground at that point.
  20. lightfighter

    lightfighter where does this go?

    Joined:
    Dec 23, 2007
    Oddometer:
    2,303
    Location:
    Sierra Vista AZ.
    Can u hook the bike up to a real shop type charger or another bike?

    Original battery? Get it load tested. 14 volts static dont rule out the battery unfortunately.