690 Rally Replica questions...

[Seth S]

Originally Posted by johnno950

where do I get these Acerbis dust lights?

[italrally]

Originally Posted by Seth S

where do I get these Acerbis dust lights?

KTM parts 690 RR

[italrally]

Originally Posted by daGeri

Which part do you mean? Position 12?

http://partsfinder.onlinemicrofiche....&c=0&d=-CLUTCH

I didn't need to remove that part. I just removed the pressure plate (Position 4) to exchange the discs and installed it, in the same position like it was before. There is a small hole in the pressure plate and on the inner clutch hub (position 9) a mark. I dont know if they belong together, but on my engine they have been on top of each other.

Still need the torque of the screws position 1 in the drawing.

I think, torque is 10 NM for the clutch spring screws, have a look to the normal RR manual.

Perfect Gerald, nobody of the other guys with the clutch solutions told here that exactly like you with the two marks at the parts 4 and 9.
So may be i don't need 10 hours to solve the problem.

[Bruno T .]

Originally Posted by italrally

I think, torque is 10 NM for the clutch spring screws,

Yes, 10 Nm is correct.

[daGeri]

Originally Posted by Bruno T .

Yes, 10 Nm is correct.

Thank you Bruno and Michele

[Bruno T .]

Originally Posted by johnno950

Friend has had a fantastic paint job done on his rr,went and had a look today

Cyril Despres 07 copy, I like it.

[F650Dakar_Norway]

Originally Posted by daGeri

Which part do you mean? Position 12?

http://partsfinder.onlinemicrofiche....&c=0&d=-CLUTCH

I didn't need to remove that part. I just removed the pressure plate (Position 4) to exchange the discs and installed it, in the same position like it was before. There is a small hole in the pressure plate and on the inner clutch hub (position 9) a mark. I dont know if they belong together, but on my engine they have been on top of each other.

This was a mystery to me too. Allow me to clarify - ( english is not my best language for technical descriptions.... ):

Part # 4 - pressure plate is the culprit that needs proper alignment with that small hole versus the mark on # 9 inner clutch hub.

I waited until a meeting in august before installing these parts - and promptly failed to notice these marks during late hours. Took a full night to curse through... and paid the price by being thoroughly ridiculed for coming 10 hours late for that meeting and missing the good riding opportunities )

Good job before someone told me about these mysterious marks over a month later on this forum

This motorcycle is still a bit mysterious - courtesy of KTM Racing secrecy, but we learn a bit every year between us happy owners

[daGeri]

I have been bored when I came home from work and anyway I had to open the clutchcover again becasue I fastened the screws with the wrong torque. So I made some pictures for you.

The “How to” of the clutch modification described by „690RR“


Which parts do I need?

1x 75032111100 Lining disc cut out (28,20€)
1x 58632016000 Rondella AntiVibration Set (41,77€)


Which tools do I need?

o) Driver Drill with ¾” adapter for socket’s or manual wrench
o) small extension (not necessary! But it makes working a little bit more comfortable)
o) 8mm socket
o) 5mm HEX
o) 2 small flat screwdrivers
o) Torque wrench






How much time will I need?

About 15-30 Minutes.



Can I do it when I’m no mechanic?

Ask yourself a question. “Am I able to change the light bulbs of my bike?” If the answer is yes, go on.



1, Clean the bike!


2, You don't need to drain the oil. Just leave the bike on the sidestand. No oil will leak from the small clutch cover.


3, Remove the 6 screws ( 5mm hex ) of the small clutch cover





5, Loose the 6 ( 8mm socket ) screws on the clutch compressing the springs. You don’t need to take them out. Just loose all of them and remove the hole cover.
I also marked the hole I mentioned. Our mysterious “mark” on the pressure plate?! J








What I marked here is the “mark” I could see on the inner clutch hub. As I said. I’m not sure if they really belong together but my clutch worked well after assembling everything.





6, Remove all the discs. I used two small flat screwdrivers. Worked quite well. If someone has a better way please let me know.





That should be on your workbench now (already without the last lining disc!)



7, Leave the most inner lining disc away and put the new one in the clutch hub. 75032111100 Lining disc cut out
Can anyone please let me know if it should be covered with oil before? I heared that you should put a clutch into oil before installing. Anyway I put a littlie bit on.

Here you can see the difference of the old and the new one. The new one has a bigger inner diameter.



8, Now you have to take care. The AntiVibration Set includes two disks. A thin (0,6 mm) flat one and a thicker (1,5mm) one with an angle. First insert the thin flat one and then the thicker angled one. The angled one needs the INNER diameter looking INSIDE the engine the OHTER diameter OUTSIDE. I tried to make a picture for you but it was impossible with my camera. Hope you understand it anyway.

What you will have now looks like this.




9, Put all the discs in again in their previous position.
(WITHOUT THE INNER LINING DISC WE ALREADY EXCHANGED WITH THE NEW ONE)


10, Put the pressure plate on (take care that the marks are on top of each other and fasten the 6 screws with 10 Nm using a torque wrench.

11, Close the small clutch cover with the 6 screws 6 Nm




Got it? :-)

[F650Dakar_Norway]

Excellent, daGeri. Nobody ever visualized this to me before. Thanks

My only commentary is that you don't need to lay the bike on its side. Both me and Vlado ( inmate 690rr ) successfully did the mod simply with the bike on its sidestand. No oil will leak - trust us on that one

[daGeri]

Originally Posted by F650Dakar_Norway

Excellent, daGeri. Nobody ever visualized this to me before. Thanks

My only commentary is that you don't need to lay the bike on its side. Both me and Vlado ( inmate 690rr ) successfully did the mod simply with the bike on its sidestand. No oil will leak - trust us on that one

Perfekt. So you should be able to do it in 10 Minutes
Thank you for mentioning that! I will delete the point above.

[shebanano]

Muchas gracias, many thanks, muchas gracias, many thanks,muchas gracias, many thanks,muchas gracias, many thanks,muchas gracias, many thanks,muchas gracias, many thanks,muchas gracias, many thanks,muchas gracias, many thanks,

I have long been following this issue, but the problems of understanding the language I was afraid to do the work and mess something up by not understanding the explanations.
Tomorrow I'm going to KTM dealer to order the parts to do the repair myself. Thank you very much to all.

[italrally]

Originally Posted by daGeri

I have been bored when I came home from work and anyway I had to open the clutchcover again becasue I fastened the screws with the wrong torque. So I made some pictures for you.

The “How to” of the clutch modification described by „690RR“


Which parts do I need?

1x 75032111100 Lining disc cut out (28,20€)
1x 58632016000 Rondella AntiVibration Set (41,77€)


Which tools do I need?

o) Driver Drill with ¾” adapter for socket’s or manual wrench
o) small extension (not necessary! But it makes working a little bit more comfortable)
o) 8mm socket
o) 5mm HEX
o) 2 small flat screwdrivers
o) Torque wrench






How much time will I need?

About 15-30 Minutes.



Can I do it when I’m no mechanic?

Ask yourself a question. “Am I able to change the light bulbs of my bike?” If the answer is yes, go on.



1, Clean the bike!


2, You don't need to drain the oil. Just leave the bike on the sidestand. No oil will leak from the small clutch cover.


3, Remove the 6 screws ( 5mm hex ) of the small clutch cover





5, Loose the 6 ( 8mm socket ) screws on the clutch compressing the springs. You don’t need to take them out. Just loose all of them and remove the hole cover.
I also marked the hole I mentioned. Our mysterious “mark” on the pressure plate?! J








What I marked here is the “mark” I could see on the inner clutch hub. As I said. I’m not sure if they really belong together but my clutch worked well after assembling everything.





6, Remove all the discs. I used two small flat screwdrivers. Worked quite well. If someone has a better way please let me know.





That should be on your workbench now (already without the last lining disc!)



7, Leave the most inner lining disc away and put the new one in the clutch hub. 75032111100 Lining disc cut out
Can anyone please let me know if it should be covered with oil before? I heared that you should put a clutch into oil before installing. Anyway I put a littlie bit on.

Here you can see the difference of the old and the new one. The new one has a bigger inner diameter.



8, Now you have to take care. The AntiVibration Set includes two disks. A thin (0,6 mm) flat one and a thicker (1,5mm) one with an angle. First insert the thin flat one and then the thicker angled one. The angled one needs the INNER diameter looking INSIDE the engine the OHTER diameter OUTSIDE. I tried to make a picture for you but it was impossible with my camera. Hope you understand it anyway.

What you will have now looks like this.




9, Put all the discs in again in their previous position.
(WITHOUT THE INNER LINING DISC WE ALREADY EXCHANGED WITH THE NEW ONE)


10, Put the pressure plate on (take care that the marks are on top of each other and fasten the 6 screws with 10 Nm using a torque wrench.

11, Close the small clutch cover with the 6 screws 6 Nm




Got it? :-)

Gerdi, what a perfect description, will try it next weekend on my bike again.
I give you that
Hopefully the ugly white stuff lying around the streets has gone finally

[Johnnyktm]

Perfect!!! This "how to" is very interesting, even for those, like myself, that do not own a 690R ;-)

[italrally]

Originally Posted by Johnnyktm

Perfect!!! This "how to" is very interesting, even for those, like myself, that do not own a 690R ;-)

Sorry, it's not for the 690 R it's for the famous 690 RR !!!

[Gerduro]

Originally Posted by Seth S

where do I get these Acerbis dust lights?

I swapped to the LED ones like on the 450 RR. You can buy them for 15 Euro and they have two connections a) Rear Light and b) Brake Light. If you connect the brake light as dust light nobody will miss you in the dust.

The Acerbis are very poor and dont add much more safety. I still have a old set somewhere if you really want them ....