New and improved KTM690 WUNDERFEST

[Buzztail]

I bet it's just too close to the Honda I finally had to park the DL650 and the Sporty in between the 690 and the Ascot. Otherwise they would just bicker all the time.

When I had the same symptoms you did, it was a small leak in the line. Plenty of volume, and no pressure.

Now can you get it back together for ANF this weekend?

Originally Posted by Mini Trail

I spent the last couple of weeks building this high-tech test rig and clean room to test out the fuel pump. You may be able to see what I think is the issue in this video.

[BK.RD.RNR]

Originally Posted by modeselector

Trying to picture the "extra loop" part. Would be interested in seeing a close up picture of your set-up.

Also curious - anyone carry a spare quick connect (fuel line) piece as part of your parts/tool kit? Heard they may prone to failing.

I replaced mine with a better made one. I think I got it from Beemer boneyard? In NJ.

The last thing I would do is spend more $$ on the same cheap POS that KTM put in there to begin with.

[BK.RD.RNR]

Originally Posted by Bill the Bong

The only issue with swapping out the fuel pump is the fuel pissing out on the floor. If you have the do a replacement trailside you might end up with a serviceable pump and no fuel. Better do it in advance.

I disagree. My 08 had 30k miles on the original pump/ filter.

Carry a spare, just in case, but if it ain't broke, don't "fix" it.

[Albie]

Originally Posted by BK.RD.RNR

I disagree. My 08 had 30k miles on the original pump/ filter.

Carry a spare, just in case, but if it ain't broke, don't "fix" it.

Mine died at around 12K miles, the replacement's still going after 15K

[ktmmitch]

We have designed a 2-piece clutch cover to suit the 690 Enduro & SMC,enabling the clutch pack to be changed with removing the whole clutch casing.
This is a shot of the prototype model being CNC machined to try on the bike before production in billet.

[motoged]

Kaching !!!!


Looks good

[Sutherngintelmen]

Originally Posted by BK.RD.RNR

I replaced mine with a better made one. I think I got it from Beemer boneyard? In NJ.

The last thing I would do is spend more $$ on the same cheap POS that KTM put in there to begin with.

This is the piece

notplastic

[offworlder]

Originally Posted by ktmmitch

We have designed a 2-piece clutch cover to suit the 690 Enduro & SMC,enabling the clutch pack to be changed with removing the whole clutch casing.

Brilliant ! Who better to solve this issue than Rally Raid - Bravo !
The big question is - will this (the inner detachable clutch cover) be stronger than stock ? Which models/years will this fit ?
Can you provide info re pricing and availability ?

....Now if only I hadnt just ordered a stock replacement....

[wsmc831]

Originally Posted by offworlder

Brilliant ! Who better to solve this issue than Rally Raid - Bravo !
The big question is - will this (the inner detachable clutch cover) be stronger than stock ? Which models/years will this fit ?
Can you provide info re pricing and availability ?

....Now if only I hadnt just ordered a stock replacement....

Yes, will buy this, especially if it prompts Rekluse to make an auto clutch.

[Hooked]

Does any one know of a fuel pump replacement video? If not maybe someone could post one as this is a big deal for these bikes.

[bobzilla]

[QUOTE=Hooked;20117505]Does any one know of a fuel pump replacement video? If not maybe someone could post one as this is a big deal for these bikes.[/QUO

it has been explained with pictures, part numbers , hints and how to's in this thread many times. It really is quite simple and a little reading will help you over this weak link on the 690.
If you read deeper you will find the other solutions for other problems too.

[ktmmitch]

Originally Posted by offworlder

Brilliant ! Who better to solve this issue than Rally Raid - Bravo !
The big question is - will this (the inner detachable clutch cover) be stronger than stock ? Which models/years will this fit ?
Can you provide info re pricing and availability ?

....Now if only I hadnt just ordered a stock replacement....

The cover will be much stronger,machined from aircraft-spec billet aluminium.
It will fit all years,and we have moved the oil filler up to the rear,to try and keep it out the dirt,as our bikes always get the OEM filler covered in crud,and is difficult to clean 100% when out on trail/rallies.
Prices will be confirmed once we have machined alloy sample.

[StepOnIt]

Originally Posted by ktmmitch

The cover will be much stronger,machined from aircraft-spec billet aluminium.
It will fit all years,and we have moved the oil filler up to the rear,to try and keep it out the dirt,as our bikes always get the OEM filler covered in crud,and is difficult to clean 100% when out on trail/rallies.
Prices will be confirmed once we have machined alloy sample.

Just an Idea and you can make fun of me if you want....Would it be possible to make the cover so that both oil filters were the same size? For me it always seems when I go and get them the only have stock of the one size

[DirtJack]

Originally Posted by Hooked

Does any one know of a fuel pump replacement video? If not maybe someone could post one as this is a big deal for these bikes.

No video, but this thread has lots of pictures beginning about page 5 and continues with Uller's tutorial on page 7. I disconnect the fuel line quick disconnect under the seat, remove my Leo Vince, and bottom tank (sub-frame) thru bolt and tip the tank up. Use a funnel with hose to catch most of the fuel. Do this in a well ventilated area as some fuel goes on the shop floor usually. Drop out the fuel pump housing and carefully pull out the pump, lines, and filter.

[Mini Trail]

Originally Posted by Buzztail

I bet it's just too close to the Honda I finally had to park the DL650 and the Sporty in between the 690 and the Ascot. Otherwise they would just bicker all the time.

When I had the same symptoms you did, it was a small leak in the line. Plenty of volume, and no pressure.

Now can you get it back together for ANF this weekend?

I won't have it together this weekend. I did an event yesterday and now I don't have a trailer. I would do ANF anyway if it wasn't for the 12 hour drive. Plus the added insult that you can be sleeping in your bed in 5 minutes.

That garage is full of Hondas. At least 10 if you only count the ones with tires and an engine in the frame. Only 3 if you count >100cc. It's hard to get away from them. Now that you mention it, Last year I had that 750 all loaded up for a trip to Birmingham. It was idling in the drive, I had my helmet on and twisted the throttle to clean it out and the cable snapped. I had to unload it and took the KTM instead. I didn't ride it again until this summer.