On the recommendation of one of the other 690 "victims", I decided to start a build thread based on my 2009 KTM 690 project. I'm pretty new to this type of thread, so bear with me as a fumble a bit, I'm no Flanny I've been riding and racing my 690 for a few years now and it's been a love hate relationship to say the least but I'm determined to make my 690 the motorcycle that will suit my needs. The motivation for this project starts with my attempt at running and finishing the 2013 Mexican 1000 Rally to make up for my DNF that I suffered at the 2012 edition, riding my Super Enduro. The big bike was plenty of fun on the dry lake bed but was a bit of a pig in the whoops and rocks. I really like the chassis and motor in the 690 but the injection system and wiring, not so much. Some say that fuel injection has no business in dirt bikes but I don't think that's true, I think a properly built fuel injection system is the perfect place for a dirt bike and I hope to prove that. After some head scratching and many nights of reading and research, I'ver decided to convert the 690 to a MicroSquirt fuel injection ECU http://www.microsquirt.info/ The sky is the limit with this tiny ECU and the open source nature of the software is an even bigger bonus. The cost is very reasonable and unit is well made. My friend lateapex(Matt) has offered to help me with the conversion and I'm happy to have it! Matt is the head dyno guy and Fuel injection specialist for Dent Sport garage in Boston, MA http://www.dentsport.com/ Goals for the project- *Reliability- Yea, tis needs no explanation *Better quality wiring harness- No more broken wires and wads of taped wires, separate lighting/access harness from Fuel injection harness. The plan is to use Teflon coated aircraft grade wire for longevity. *Utilize more off the shelf parts- I'm not a big fan of having to wait for parts from KTM. Sometimes the off the wall stuff takes a few weeks and costs a fortune. I'm hoping to use GM style Weatherpack sensors or Bosch sensors, for cost and availability reasons. If for some reason, a coolant temp sensor fails, it would be nice to walk into a Napa in AZ and buy a new one for $18.00. This also applies to injectors.... $200 for a fuel injector The throttle body will probably stay, it fits on the motor pretty well and it looks like the TPS is the only wild card. Hopefully they're reliable but if not, we can have the system run on MAP in a pinch... try that with the stock system *Servicing- My number one complaint about the 690 is servicing it... that stock air box is a torture device and the wiring wad in the back is a pain in the ass. The plan is to relocate the battery to the front of the frame, just behind the radiator on a custom aluminum "tray". Also mounted on the tray will be the ECU and circuit breakers for all the consumers. The tray will be attached to a frame that is bolted to the bike frame using Dzus fittings for easy removal. The Air filter will be located in the rear of the 690 where the battery once resided, for easy replacement and cooler charge air. Valve clearance checks will be a snap and the wiring will all be condensed in that localized area instead of stretched all the way to the back and front. *Power- Not really interested in getting more HP, or to put it another way, it's not my focus. If through the process we pick up a few HP, I won't be sad but I'm more concerned with ridability (is that a word) and reliability. Sakurama put it very well in his thread in OC.... Dyno's don't ride bikes, which is true. Please feel free to offer constructive criticism, I welcome it and look forward to any ideas or thoughts. The goal for this project is to test the 690 out at a 3 hour endurance ice race in WI in January, I did it last year and had a blast! http://www.steelshoefund.org/home.html Thanks for stopping by!