KTM 690 SM - Helping out a friend

[Archangel]

So the reason it fealt like I ran out of fuel is because I ran out of fuel. I was under the false illusion that the fuel gauge was working...



Note to self: trust nothing on this bike.

I have also found some other dodge wiring setups!



And what seems as a crack in the intake to the throttle body...



Sent from my SM-G920F using Tapatalk

[Archangel]

Trying to figure out this wiring setup here. Following the wire, it does run down into where the gear selector sits, but there are other cables running in there too.

[geopat]

oh shit looks like someone went to town on that bike  good luck mate

[Amsterdam]

My 2c - maybe it helps your cause and maybe not

I once had a 690 that ran kak - turned out it was sucking in air at the throttle body

check that the rubber boots and clamps are tight and properly sealed from

airbox to throttle body
and
throttle body to intake manifold on engine side

An easy way to check this is when the bike is idling you just spray a bit of Quickstart at the throttle body.  If the revs increase then there is a leak.

[Archangel]

OK, just a quick update here...

The fuel level sensor is a thermistor and apparently it keeps cool inside the liquid and then heats up when the fuel level drops below the sensor resulting in an increase in resistance. In other words, when submerged, it should read a small resistance and a high(ish) voltage output while removed from liquid, it reads roughly 1k Ohm and results in a low(er) voltage towards the output. New fuel sensor from KTM is R750, but I'm busy with a hack. More on that later...

I have removed the rollover sensor and bypassed it with the proposed resistors of 3.9k between Blue and Yellow/Green and 800 Ohm between Yellow/Green and Black as per this post.

I have removed the side stand switch and inserted the proposed 2.2k Ohm (some suggest 1.8k Ohm, tbc) instead of just cable tying or heat shrinking the trigger to the pickup, because if the pickup is faulty, that solution won't solve the issue.

After some more digging, I found that this connector had nothing plugged it. After a bit of trolling online, it looks like the "purge valve", which leads me to believe that this bike has undergone a "canisterectomy", but it may have been done half-ass.

[Archangel]

Now that this is said, any idea what this LightGreen/White wire is for? The wiring diagram shows Green/White on both the throttle stepper motor (towards EPT) and acceleration position sensor (towards ECU).

[Jacobsroodt]

Lyk my jy is kniediep hier in! Sterkte!

[Archangel]

Close... One of the fuel lines was disconnected.

Have to admit that it wasn't me that fixed it. I used MellowJo's trailer to pick up the bike, so the bike was at his spot. They had people over Friday night, so I couldn't go and collect work there. Then I had a 1st birthday party this morning, followed by monthly groceries, so I haven't had time to go over there to tinker or investigate. Just as we got home at around 16h, he stopped at our place with the bike. His words "Sorry that I didn't wait for you to work on it".

I think he was worried about a) his Beemers picking up this KTM temperamental sickness, b) that he'd fall in love with this bike while it's there, c) the missus might have frowned about another pony in the stall or d) there may actually not physically have been any more space for another bike. Either way,  he wanted to get it out asap so the bike is at my place now and he can rest easy.

Come on, show them the video of the KTM on BMW Life support … 

Just a post to give credit where it is due.   

Thanks Dad! 

[Archangel]

Some more updates.

This is what the spark plug looked like...     

And this is a video of somebody else with a similar scenario. 

I have replaced the spark plug cap with a new plug cap.

[Archangel]

For those wondering about the difference between the SM and SMC... 

[Archangel]

I finally managed to get some of my other home projects done, so I ordered the SAS block off plate and the TuneECU cable which will hopefully enable some more progress on this bike...

[Archangel]

Quick update in general:

The SAS plugs were disconnected, so I actually just removed all the tubing and plugged the SAS for now. I'll disable that on the map once the TuneECU cable arrives.

I'm also in the process of collecting the correct resistors to plug into the roll over and sidestand sensors, disabling them both completely and essentially checking them off the list of potential issues.

[Edgar]

Jy het baie baie geduld, as dit ek was het ek die bike laaank reeds verkoop. Sterkte daar! 

[Archangel]

Jy het baie baie geduld, as dit ek was het ek die bike laaank reeds verkoop. Sterkte daar! 

Dis lekker om 'n ander man se probleem op te los, want ek het niks om te verloor nie.   

Maar ek geniet dit om te probeer uitfigure, leer en dan ultimately fix.

[Archangel]

Another update:

Last Friday, I decided to ride the bike to work (Melkbosstrand to CBD, 30km) and it wen't OKish. The bike stalled maybe 3 - 4 times, but started almost immediately after so no real issue. On the way home, I decided to stop at KTM to get some input from them. They were very helpful and quickly plugged in the diagnostics to see what faults were coming up. After resetting all the historical faults, we started the motor and it died a few seconds later without any faults logged. Some more fiddling showed that the TPS settings were supposedly way out of range, so they reset that to within the proposed spec and voila... Nothing.  The bike didn't want to start at all.

After some more fidgeting, we finally got the bike running and I was keen to just jump on and get home, as it was after 4pm on a sunny Friday! I made it all the way to Lagoon beach before the fist stall, then to Woodbridge Island for the 2nd leg and it finally died at Paddocks. By that time, the battery ran out and I was stranded. 

I parked the bike at Paddocks and got a lift home, collected again later that weekend and it's now back in the garage and I'm back to the drawing board. 

PS. The intention of this post is not to reflect badly on KTM Cape Town (it's not their fault), I'm just frustrated with the situation. 

[geopat]

Are you 100 percent sure you are not having battery problems? Maybe a charging issue ? Low voltage will cause the bike to do funny things why was your battery dead by the time you got to Milner ton?

[BuRP]

Love the determination to get this fixed!
Keep posting until you find it please, 

[Archangel]

Are you 100 percent sure you are not having battery problems? Maybe a charging issue ? Low voltage will cause the bike to do funny things why was your battery dead by the time you got to Milnerton?

Battery was dead from the number of times I had to swing the motor to get it started on the previous two stop-&-go's. And after recharging the battery at home, it started the bike just fine. Even after standing for a week, it started up again without issue.

Love the determination to get this fixed!
Keep posting until you find it please, 

Thanks, I have now ordered a new (2nd hand) TPS and EFI (75041031000 & 75041032000) controllers from ebay to eliminate them from my long list of potential causes.

[Welsh]

I find it strange no faults showed up? 

[Manic]

As hy die bike wil verkoop pm my eerste