New and improved KTM690 WUNDERFEST

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

  1. MeinMotorrad

    MeinMotorrad Long timer

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    I've been wondering about doing something similar but I have some worries about the filter, water etc. My plan was to cut the air box up to make into tool storage.
  2. RuckedUp

    RuckedUp Long timer

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    I was pulling out of a gas station in AZ yesterday and went to apply the rear brake and nothing. I stop and have a look, the brake pedal is hanging down and the return spring was broke. I put a zip tie on it and continued toward Flagstaff where I was able to get a bolt and spring at a local KTM dealer just before they closed.

    Does anyone have a link to a "how to" on pulling off the brake pedal? It looks like I may have to pull out the main bolt that holds on the swing arm or maybe take off the brake line assembly. I just hope the bolt did not shear off them Im dead in the water with 800 miles left to get back home.

    Here are a few photos of the broke lever as well as some shots on the desert riding we did yesterday.

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    few trip photos so far

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  3. ba_

    ba_ Long timer

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    For those that installed a billet fuel filler adapter what did you do with the vent hose?
  4. dad2bike

    dad2bike Cranky Old Fart

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    I put a set screw in mine. I use a stubby vent hose on my cap. That allows me to fill to the brim.

    Sent from outside my mind.
  5. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Here's what I did-an easy $5 fix that pretty much guarantees no ingress of dust and crap into the fuel system.

    http://advrider.com/forums/showthread.php?t=906974

    Dirty
  6. ba_

    ba_ Long timer

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    I'm confused.

    The hose that is attached to the OEM fuel filler is a vent hose for the tank correct?

    The billet adapters that a) give you a taller filler neck and b) eliminate needing the key typically have a plastic cap that has a breather hose out the top.
  7. Seth S

    Seth S Will _____ for _____

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    You just remove the bolt on the swingarm pivot..its a 17mm or 19mm..cant remember. The bolt threads into the swingarm pivot bolt but is not the actual pivot...it should be pretty apparent when you get it loose. Then take out the two 10mm bolts that are in the bottom of the foot peg mount (they have torx heads on the inside). The footpeg bracket will slide off then. The bolt that holds the brake lever on is reverse threaded...so cw to loosen.
  8. v8toilet

    v8toilet Nothing to see here.

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    I'm not sure I know the early years were left hand thread but for some reason thought later models were normal.
  9. RuckedUp

    RuckedUp Long timer

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    Thanks I have the brake back on now. I was thinking the bolt went all the way thru to the other side of the bike. To easy to do wish I had installed the beefed up brake lever before I left now! Going on when I get home!
  10. The Letter J

    The Letter J lost in the 690 mega

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    Many of the aftermarket fuel fillers (Renazco, CJ designs, etc) have the vent exiting in the stock location with the one on the cap itself plugged off with a vacuum cap.
  11. ba_

    ba_ Long timer

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    Thanks

    Since the Rally Raid one doesn't have that I'll just leave the stock hose alone not connected to anything

    I only looked at it for a minute or two -- where is the other side of that hose?
  12. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    J got it.:freaky

    Man I'm loving this bike of ours!:clap:clap

    Dirty
  13. CanadianX

    CanadianX Oh!? That is deep.

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    Mounting some auxiliary lights and am looking for a switch to mount on our fat bars. Anyone have a source or ideas, pics of what you did to your dash to run lights etc?
  14. chrislitt

    chrislitt B-KTM-W

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    Now that I need the fuel capacity for a May ride with the RMAR group I installed (started the install) the rally raid tanks I've had for awhile. I put it off as long as I could because the idea was to add the tanks, upgrade the regulator/rectifier (rr), and change the fuel pump, and the shock collar, then run tuneecu- time to do this has been hard to find. Looked for ideas on this thread for mounting the mosfet with the tanks and just found one that didn't thrill me (though my way isn't better!). I ended up using the rally raid tank kit rr mount but rotated the plugs to pointing skyward. This required removing some fin meat. But I checked the voltage output with engine running while the old fuel system was still installed and it was fine. It sits in a an area where there is a lot of air movement coming thru the radiator so hopefully it won't miss the cooling area.

    I am now attempting to install the CA Cycleworks fuel pump while making the fuel connection change required by the Rally Raid tanks. The problem is that the new hose end that connects to the fuel filter is too f**cking small. Too small as in "it ain't ever going on." Obviously I am going to call CA Cycleworks in the morning and see if they have any ideas. Am I missing something? I suppose it would go on if I trimmed the pipe off the fuel filter so that the nub was removed. That is a bad idea though. BTW, everything is sparkly inside the tank and should be at 2600 miles. The fuel hose furnished with the replacement pump was the black one that resembles the original.

    And another thing. Has anyone knocked the fuel outlets off their rally raid (evo2) tanks? Now that they are on the bike they look entirely too exposed.

    I remember someone way back in this thread, I think, lamenting that he might be making the bike less reliable by making a bunch of mods. On a road blocked Sunday afternoon I am wondering the same thing.

    Mostly I hope I'm missing something so that I can put this thing back together today. But that isn't going to happen until I like the connections.

    Ideas and positive comments will be appreciated. I would even take a negative comment if it would solve this issue!

    Stuck on Sunday (at least I am in the garage)
  15. carlosbarrios

    carlosbarrios Been here awhile

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    Check out Ddgfarm's post below:

    http://www.advrider.com/forums/showpost.php?p=23725902&postcount=14694

    I'm about to dive into this myself, as I also purchased some EVO2 tanks.

    Ddgfarm is a friend of mine, and I ended up buying the same filter and pump that he bought. Seems what he did should work fine.
  16. Seth S

    Seth S Will _____ for _____

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    Check out highway dirt bikes top clamps.
  17. Bumpaman

    Bumpaman Been here awhile

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    There is a quick disconnect in the fuel lines of these 690's? I accidentally broke the quick disconnect on my 2010 and just replaced it with a single length of 5/16 fuel injection hose from tank to injector. Is there a potential problem with this I am not seeing? Thanks.
  18. PilbaraGoat

    PilbaraGoat Been here awhile

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    Yo Bumpamann I did that about 700kms ago and have no troubles yet
  19. chrislitt

    chrislitt B-KTM-W

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    Stockton, CA

    His use of the Napa 5/16 hose makes sense but the outlet pipe of the ca cycleworks pump is bigger than the Mahler fuel filter in my case. There must be some differences within year models. I hope ca cyclworks has some ideas.

    It's sort of coincidental to be conversing with you upstaters. I was in Geneseo earlier this month for a couple of days. It was way, way too cold for this central valley California boy. I like the open, rural country though. It is beautiful.

    Thanks for the help.
  20. isaac004

    isaac004 Been here awhile

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    I installed the CJ Designs fuel filler neck on my 2014 yesterday. The CJ has a vent built into the side, so I installed the stock vent hose to that. The stock vent hose goes to the charcoal canister, which I will probably remove in the near future. With the vent on the side of the CJ fuel filler neck, the plastic cap (Acerbis) just has a rubber plug over the top. This means in the future when I take off the charcoal canister, I will just install a one way breather valve on to the CJ vent. You will want to keep it vented to atmosphere if you take the charcoal off, either through the side of the fuel filler neck or the cap.