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Greetings boys and girls, I recently became the proud owner of my very own KTM! A 2009 690 Enduro R (sitting just under 10k miles). I have lusted after this bike for many years and finally had the extra cash to pick one up. However, it hasn’t all been good. In the very short period of time I’ve owned it, it has left me stranded 3 times! I have been playing catch up on all the previous owners maintenance that he had “deferred” and in the process, trying to accomplish the mods needed to make this rig more reliable. I’ve got to say that when it is running, it is probably the most fun thing on two wheels. It eases the sting a bit for when it breaks down. Anyways, I digress… lets get down to the current issue at hand. Current Problem: Click here to see a video of what it does Once the bike is fully warm, usually after I have been riding around for 1-2 hours, the bike will all of a sudden start to sputter (as if it is suffering from a fuel cut) and eventually after a few moments it will die altogether. The problem can be more quickly brought on if I am riding around town in stop and go traffic in the hotter part of the day. The bike will start right back up again but will generally sputter and die again within 10-30 seconds if you continue to ride around. Or if you start it after it initially dying and let it idle, it can idle for up to a minute before it dies on its own. The main thing to take away from this is that it only does this when it is really hot. (usually 4 bars on the gauge, that’s as hot as it ever gets with the fan switch mod) I should also mention that there is no blinking FI light. Secondary problem: Sometimes when you start the bike the dash will flash the wheel size measurement on and off: “LENGTH 1870” and a couple other symbols for a few seconds to half a minute before it displays the speed and all the regular information. I don’t think this is related to the issues but I thought I’d make mention of it. Current mods and notable part replacements: *Akro Slip on *K&N drop-in air filter *Power Commander V with tune for pipe and intake (from Rottweiler) *CA Cycle works Fuel pump (less than 200 miles on it… the OEM one died a couple days after I bought the bike) *New in tank fuel filter (bike does not have an inline filter) *New KTM injector (less than 100 miles on it… old one dribbled fuel causing hard starting after sitting) *RR Manual Cam Chain Tensioner *New NGK spark plug *KTM Twins Low temp fan switch *-15 Exhaust Rocker *Valves recently lashed and are in perfect spec *All the emission components are removed What I’ve done so far: *Completely disconnected the Power commander from the bike and ran the bike in stock ecu config- the problem still occurs *Checked all electrical connections and took apart the bike and went over the entire wire loom - no defects noted *Checked the battery with a multi meter with the bike off and running, battery appears perfectly healthy both static and running *Swapped back to the old leaking injector – problem still occurs *Disconnected the tip over sensor – this causes an FI light, the problem still occurs *Disabled the kickstand sensor with a dongle – the problem still occurs *Replaced the voltage regulator with a nice mosfet unit, didnt fix the problem but the regulator runs so cool now! *Put a meter on the ignition coil and spark plug connector, both of these values read almost dead nuts in the middle of the specified range *Put a meter on the stator connector, the manual says the resistance should be less than or equal to 1 ohm at 68 degrees F. Both my measurements read 2.1 ohms, but its also about 80-85 degrees in my garage... so I'm not sure if this is acceptable or not? Possible ideas: *Throttle Body Sensors/ blade gears - This is something I'm hesitant to get into since if I mess with it and take it to the dealer I wouldn't want them to blame me for messing with it. I only say this because my dealer told me that KTM has warrantied complete throttle bodies for 690's before- even on older bikes like mine. *Fuel pump – God forbid this would be the issue since I just replaced this… but it seems like the bike is suffering a fuel cut and I know that they tend to have issues when they get hot… but every time this problem has occurred I’ve had at least 2 gallons of gas in the tank… I also triple checked my hose routing when I installed the new fuel pump/ filter and made sure it didn’t kink as it went in. *ECU failure - just grabbing at strands here... maybe its fudgin up when it gets hot for some reason. _________________________________________________ Sorry for making yet another 690 thread… Thanks for reading this, ANY input is appreciated. I will try to keep this organized as I remember to add things so it is somewhat easier to read over. THANK YOU
My DRZ has been very slowly becoming harder and harder to shift into neutral. Sometimes it just won't. I shift all the way down to first, and try to half upshift into neutral, and it's like i'm pulling my foot up on a solid object. I just cannot get it to upshift no matter what. When i'm rolling it seems to shift easy, but stopped is a NO GO. I just did a fresh oil change today. (Somebody said an oil change fixed his no-go neutral bike). Can somebody please help me out here? Give me some ideas maybe from 'Probable the issue' to 'could possibly be'. And i'll go down the list and try to get this solved. Thanks in advance peeps.