New and improved KTM690 WUNDERFEST

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

  1. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    For this type of hose clamp?

    [​IMG]

    I've always wondered how I get those freakin' things off AND wonder what sort of tool I'd need to clamp them.

    Do I need a new tool?!?!?!

    Dirty
  2. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    Yes and no. The type shown above with "ratcheting" notches can sometimes be assembled with waterpump (aka channelok) pliers.

    The solid-band type is best done with either a modified (dulled) "hoof cutter" plier or a proper tool.

    Here's everything you need to know, and more:

    <iframe width="420" height="315" src="//www.youtube.com/embed/T83W2QrYGbM" frameborder="0" allowfullscreen></iframe>

    To remove the ratchet type, grab the loose end and lift it off the tab. It's possible to use a small screwdriver to spread the solid band crimps, but the crimped hose is usually damaged with this method. The crimp itself is easily cut off with the above-mentioned hoof-cutter pliers, which look like this:

    [​IMG]
  3. Uller

    Uller Long timer

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    The tools posted by Cyborg are for a different, plastic quick release fitting that is part of the fuel line. Go look at the microfiche of the fuel system and you will see the connector that needs a special tool to operate.

    The clamp you posted holds the hose to the fuel pump/filter/regulator

    To easily get them off, take a small flat head screwdriver the slide it between the bands at the end of the overlap. You can see the spot in the pic above. It is where the ends are tapered, just before the holding tab. Then twist. It will easily release the tab and the clamp.

    You can order the tool and clamps from Motion Pro

    http://www.motionpro.com/motorcycle/partno/12-0078/

    I like the side jaw set for the hard to reach places.

    http://www.motionpro.com/motorcycle/partno/12-0073/

    You can also buy larger quantities (25 +) from McMaster-Carr for less $

    http://www.mcmaster.com/#ear-hose-clamps/=nrz989
  4. TheMuffinMan

    TheMuffinMan Forest Ranger Magnet

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    I dremel those off and then replace them with something I can take off trail-side in the middle of nowhere if I have to.

    For fuel lines I buy the fuel injection clamps with a screw (not the standard hose clamps with a screw) for everything else that's low pressure I usually do regular hose clamps or plastic zip ties if it's thermally viable.


    's just me though.
  5. cyborg

    cyborg Potius Sero Quam Numquam

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    For those who are not familiar with the connectors Uller and I were talking about, the KTM690's have basically the same exact parts inside the tanks as my Berg FE390. Carrying the one small plastic remover tool in the toolkit would not be too bad if you wanted to stay OEM, at least within the warranty period.

    It's the round connectors/couplers at the top of this 690 Fiche pic

    [​IMG]




    I also did safety wire the cap on my Berg 390 fuel pump and will do that to my 690 fuel pump when I get to opening it up. Note that my fuel pump lower housing is metal (for the 70degree Tank I have on it, but the OEM body is normally black plastic.

    [​IMG]
  6. MeinMotorrad

    MeinMotorrad Long timer

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    Hmmm. I'm going to get stuck into the tank when the clips are delivered. I didn't safety wire in the pump, I wonder if this is an issue.
  7. gen

    gen Been here awhile

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  8. DirtJack

    DirtJack Adventurer

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    You can also use regular side cutter pliers to cut off the crush clamps. You don't want to use a hoof-cutter to install (crush) a new clamp. As someone mentioned, you can get the install tool from Motion Pro, but I bought mine from Lowe's in the plumbing section. $19.00 This tool is usually located in the area where 1" or 1 1/4" black PVC above ground water line is sold. In Texas this PVC is often used on ranches to plumb water to stock tanks, etc. fastened with crush clamps.
  9. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Who's hiding that LIKE button around here?

    Dirty
  10. DirtJack

    DirtJack Adventurer

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    FaceBook, never heard of it. :huh
  11. DirtWarrior

    DirtWarrior Adventurer

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    Thanks! I'll grab one tomorrow at Napa.
  12. CordR

    CordR Been here awhile

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    Does anyone have any experience with one of these?

    http://www.trailtech.net/040-HMS-A3A.html

    [​IMG]


    I've searched through this thread and others and seem to be getting mixed reviews/responses.

    A riding buddy has this one on his 690 but it came with the bike when he purchased it......though he swears by it.

    I've seen people discuss the Leo Vince one and this Trail Tech one....but this TT one does not list the 690 on the web site. A few others have made their own, but I won't be going to that level of effort.....and I'd screw it up.

    I emailed TT (and KTM Twins because Twins also sells the same switch) and they basically told me the same thing. 'we haven't actually fit one to a 690 so we don't know' or 'the box doesn't list 690 so we aren't sure'.

    I'd like to confirm if possible that it's ok on the 690, but you'll only get to use 3 of the 4 map settings since these switches only have the 3 settings. Then it's just a matter of making sure I can use settings 1, 2, 3 (as opposed to using 0, 1, 2) etc.

    Any firsthand feedback would be appreciated.

    My primary goal is to be able to access setting #1 easily when I get into slippery conditions. I played with that in a rather wet ride back in May and I found it quite helpful. But on my two week trip coming up in Sep, I'd rather not remove the seat AND the GL luggage just to get at the switch.


    thx

    Cord
  13. cyborg

    cyborg Potius Sero Quam Numquam

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    I have the TrailTech unit on my Berg FE390 and like it so I ordered the "orange" one you show above for my 690. It has not arrived yet.
    My guess is there is no plug-in up at the headlight area and will probably have to wire back to the under-seat switch harness. Also I will need to verify the TrailTech switch has the correct Ohm values before I install it.

    Measured from underseat map switch:
    0 = Poor Fuel = open/infinity
    1 = Soft = 14.9 Kohm
    2 = Advanced(Wild) = 6.8 Kohm
    3 = Standard = 4.7 Kohm

    If the measured values on the TrailTech KTM map switch version are close to these values then it should work fine, other that it probably won't be plug-and-play and will need a bit of custom wiring. If the TrailTech KTM map switch does not have the correct values, I also know how to modify it...:evil

    The 4th map you can't used from the switch would be "0" = open, the "poor fuel" map, and that could just be a bullet connector(for example) under the seat or up in the front mask for those special situations and the bullet connector would break the line on one of the two wires from the TT map switch. I'll take pictures when I do the install.

    Noticed my '13 690 Enduro R also does not seem to have a plug under the front display for the Tripmaster switch. I have a Tripmaster switch on my Adventure 990S and on my Berg 390, but again nobody including KTMtwins knows of a Tripmaster switch for the 690 Enduro, even though the Duke has one available as an option. These bikes have been out since '08 so I'm amazed nobody seems to know about these yet.

    Speaking of wiring, I haven't received my shop manuals from the dealer yet so I need the wiring schematic if someone would be so kind as to PM me that. Thanks!
  14. CordR

    CordR Been here awhile

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    Thanks, Cyborg. Your pics and info would be helpful.

    I've seen a lot of people discuss it, but I haven't seen anyone come back and say ok, I bought it, here are the results, etc....


    Thanks,

    Cord
  15. RoninMoto

    RoninMoto Wanderer

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    Cord,
    Easy cheap way to do it. Cut the wire with the plug on it and extend it long enough so you can mount the potentiometer somewhere up on the front of the bike. It doesn't matter if you switch the wires... I did this a few weeks ago.
  16. ktmmitch

    ktmmitch Been here awhile

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    We designed our own injection-moulded disconnect tool for the push-fit fuel connectors,which can be attached to a key-ring,so you have it ready when needed.
    As its plastic,it does not damage the connector,and its ORANGE!!

    http://www.rally-raidproducts.co.uk...ance-upgrades/ktm-fuel-pump-disconnector-clip[​IMG]
  17. mbrick

    mbrick Been here awhile

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    I ordered a new 40T OEM Sprocket from the dealer P/N 75010051040. Came with the KTM P/N and barcode sticker on it, but it is a PBR Sprocket and in their packaging. Are they an OEM for KTM?

    I've never seen a part from another manufacturer with a KTM P/N sticker just added to it so I am curious.
  18. dad2bike

    dad2bike Cranky Old Fart

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    I'm planning on picking up a rear wheel lift at cycle gear today.
    What size is the thread for the spools on the swing arm?

    Sent from outside my mind.
  19. cyborg

    cyborg Potius Sero Quam Numquam

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    Hi John, that's a nifty bit to have in the bike toolkit, had not seen that before until this thread, and orange makes it near irresistible. :D

    I bought my NAPA set (6 sizes for $12) a year ago for my Husaberg FE and they didn't have them in blue :cry :lol3
  20. Albie

    Albie Kool Aid poisoner

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    Finally swapped out my Leo V can for a FMF Q4. The Q4 is definitely more quiet so I'm happier.

    [​IMG]