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Old 12-23-2012, 03:17 PM   #6646
Mudguts
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The rally cam produces 6+hp all in the hi rev range ,but you lose a lot of lo and mid power most of us would want more mid range as that we're we ride in the rev range , but having a 728cc monster would be a lot of fun in the outback here in Aus (as long as you have the fuel range) .


Mitch a lot of the work you are doing has already been done , Or are you looking for some thing different ?
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Old 12-23-2012, 09:07 PM   #6647
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Quote:
Originally Posted by Mudguts View Post
The rally cam produces 6+hp all in the hi rev range ,but you lose a lot of lo and mid power most of us would want more mid range as that we're we ride in the rev range , but having a 728cc monster would be a lot of fun in the outback here in Aus (as long as you have the fuel range) .


Mitch a lot of the work you are doing has already been done , Or are you looking for some thing different ?
Will the starter spin a KTM monster motor. A friend built MZ supersingles road race motors from the 660 base motor. The largest was a 760, but no starter would spin it. Had to use a roller starter.
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Old 12-23-2012, 10:08 PM   #6648
Mudguts
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The auto decomp should take care of that , there is a 800cc big bore kit for those who love power
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Old 12-24-2012, 12:15 AM   #6649
ktmmitch
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Quote:
Originally Posted by Mudguts View Post
The rally cam produces 6+hp all in the hi rev range ,but you lose a lot of lo and mid power most of us would want more mid range as that we're we ride in the rev range , but having a 728cc monster would be a lot of fun in the outback here in Aus (as long as you have the fuel range) .


Mitch a lot of the work you are doing has already been done , Or are you looking for some thing different ?
Yes we are.we are looking for a high-quality replacement piston assembly for the OEM unit,now the bikes are getting older and people are looking to rebuild,but at an affordable price to riders.We have 3 motors in bits at the moment,2 654cc enduro & a 690 Rally,and have been comparing cranks,rods etc.
By ordering a batch from Cosworth we can do a straight replacement for the OEM,stock compression,and then do others with higher comp for racers & SMC guys.
The good thing is that all the 654cc & 690cc motors,and 690 rally,can use the same design of piston,which helps our costs,as the minimum order batch is 48 pistons.
But the main reason we were looking at the piston manufacture was to allow us to alter the stroke,and if you do that then you need to re-design the crown to get the correct compression ration,unless you want to re-profile the head,which we did not want to do.
We were using the rally cam measurements as a "worse case scenario",so that we can allow for valve pockets in the piston crown to suit both cams,stock & rally.
Pistons can also be specced with different coatings,from their standard anti-scuff(green) on the front and rear skirts up to a full DLC coating(formula 1 tech) which is all over and can double the cost of the piston,but was used in this years Speedway World Champ's 500cc motor,and showed no percievable wear after a full season on the shale tracks,and these are bikes with no cooling,or rev-limiters.(i was told they hit 13,000rpm on the start line!!!!)

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Old 12-24-2012, 07:31 AM   #6650
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Originally Posted by ktmmitch View Post
Yes we are.we are looking for a high-quality replacement piston assembly for the OEM unit,now the bikes are getting older and people are looking to rebuild,but at an affordable price to riders.We have 3 motors in bits at the moment,2 654cc enduro & a 690 Rally,and have been comparing cranks,rods etc.
By ordering a batch from Cosworth we can do a straight replacement for the OEM,stock compression,and then do others with higher comp for racers & SMC guys.
The good thing is that all the 654cc & 690cc motors,and 690 rally,can use the same design of piston,which helps our costs,as the minimum order batch is 48 pistons.
But the main reason we were looking at the piston manufacture was to allow us to alter the stroke,and if you do that then you need to re-design the crown to get the correct compression ration,unless you want to re-profile the head,which we did not want to do.
We were using the rally cam measurements as a "worse case scenario",so that we can allow for valve pockets in the piston crown to suit both cams,stock & rally.
Pistons can also be specced with different coatings,from their standard anti-scuff(green) on the front and rear skirts up to a full DLC coating(formula 1 tech) which is all over and can double the cost of the piston,but was used in this years Speedway World Champ's 500cc motor,and showed no percievable wear after a full season on the shale tracks,and these are bikes with no cooling,or rev-limiters.(i was told they hit 13,000rpm on the start line!!!!)



Just finished getting all the top end stuff for mine, just need to put it all together in the next day or two. Took me forever to find a #1 piston, and of course there are NO reasonable aftermarket options. Gonna need cylinder work next time so I'm gonna probably go for a big bore.
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Old 12-24-2012, 07:41 AM   #6651
ktmmitch
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Originally Posted by Albie View Post
Just finished getting all the top end stuff for mine, just need to put it all together in the next day or two. Took me forever to find a #1 piston, and of course there are NO reasonable aftermarket options. Gonna need cylinder work next time so I'm gonna probably go for a big bore.
Good thought,I will ask if they can machine some slightly larger diameter Gruppe 2 pistons in the batch of 48, for those with higher mileage/worn barrels.
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Old 12-25-2012, 08:55 PM   #6652
johnno950
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Originally Posted by Mudguts View Post
The rally cam produces 6+hp all in the hi rev range ,but you lose a lot of lo and mid power most of us would want more mid range as that we're we ride in the rev range , but having a 728cc monster would be a lot of fun in the outback here in Aus (as long as you have the fuel range) .


Mitch a lot of the work you are doing has already been done , Or are you looking for some thing different ?
One of the other reasons the rr go like stink through the rev range is the ratois of 4th/5th/6th....very close together and bike pulls very hard in higher gears.
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Old 12-26-2012, 07:17 AM   #6653
Seth S
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A friend got a set of 4 pistons with wrist pins custom machined for a 2.0 litre 16v Saab race engine. The pistons were about $600 for the set and were build with relief for the valves. They were set up for a 12:1 compression ratio.
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Old 12-26-2012, 02:18 PM   #6654
Dotbond
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Got the FI light flashing at me over the weekend on my new 690, 450km on the clock. 1 long 3 short. I'm picking it is to do with the Airbox air temp sensor according to the manual - possible loose wiring?
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Old 12-26-2012, 02:21 PM   #6655
Albie
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Originally Posted by Dotbond View Post
Got the FI light flashing at me over the weekend on my new 690, 450km on the clock. 1 long 3 short. I'm picking it is to do with the Airbox air temp sensor according to the manual - possible loose wiring?
Probably broken wiring. The wire going to the connector doesn't have enough slack in it.
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Old 12-26-2012, 02:26 PM   #6656
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Originally Posted by Albie View Post
Probably broken wiring. The wire going to the connector doesn't have enough slack in it.
I just stripped my '11 after 7000km & have found several chafed wires. Despicable for a machine of this caliber. If I had not checked myself I'm sure I would have been left high and dry on the trail some day...
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Old 12-26-2012, 11:18 PM   #6657
Dotbond
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I took the bike into the bike shop and they replaced the temp sensor unit in the airbox with one from a Freeride demo bike they had. Said to try it out over the weekend and let them know if it fixes the flashing FI or not. Sweet!
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Old 12-27-2012, 07:44 AM   #6658
gspadafore
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Trials tire on 690?

I love using trials tire on my KTM 300 for all kinds of riding, mostly single track technical stuff. Just bought a 690 and heading to Copper Canyon soon, some pavement, lots of high speed 2 track. Anyone have experience with trials tire on 690. Assume Pirelli MT 21 might work.
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Old 12-27-2012, 10:26 AM   #6659
Albie
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I took the bike into the bike shop and they replaced the temp sensor unit in the airbox with one from a Freeride demo bike they had. Said to try it out over the weekend and let them know if it fixes the flashing FI or not. Sweet!
Every time mines ever broken the wire, or the sensor failed it never made a difference with the way the bike runs, just that annoying fault code flashing.
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Old 12-27-2012, 11:18 AM   #6660
Louisdut
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Hi all

looking at getting a spare fuel pump

CA Cycleworks Pump (155.00) or Genuine KTM (Fuel Pump & Flange kit 260.00)

Anyone had a problem with the Cycleworks Pump ?

Cheers

Louis
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