KTM 690 definitive stalling FI discussion

[DRxDR]

I have the 07 690SM, bought it used 6 wks ago. Stalled the same day I was bringing it home. Called the guy back, said never happens to him. Continued to stall every time it was rode over the next 2 weeks. After reading this thread I do not believe him, the bike has 10.5K miles and I doubt this just started when I got the bike.

Took the bike to the KTM dealer her in Thousand Oaks Ca. they had it for 1 1/2 wks diagnosing it. They said they did an all systems reset, then they tried the throttle cable tension. They called KTM direct and were advised to map it again, that did not work. They were told a few 07 & 08 models had a bad map and they have a fix for it. They put in this special map and it stopped stalling, but the idle is still eradic (going from low to high at stops). It feels strange when the idle is off like its going to stall but it holds on and levels out. Really wish they could get this right, the dealer admitted it was not perfect but they did not know what else to do at this time and at least its not stalling now.

Hopefully someone here will have the once for all answer.

Try another dealer! I bought my '07 SM from them and their tech had installed the Akra slip-ons without the gaskets in place which soon resulted in leakage and the loosening of the connector bolts. While I was redoing it I noticed that they had evidently lost some of the shield S/S Torx bolts and replaced them with some crap steel hex heads. They told me that it had the Akra remap installed, when in fact, not only was it not installed but they didn't even have the equipment on site to do it with.

All of this and more occurred in Feb of '08 which led me to loose faith in the dealership. Hopefully they have improved their service or you too may be receiving less than adequate diagnostics.

[sharky34]

... the idle is still eradic (going from low to high at stops). It feels strange when the idle is off like its going to stall but it holds on and levels out.

I have had the same symptom after my last service (5000km on my 07'690SM).

Before the service, the idle was at 1800 rpm. At service, the tech changed the reluctor ring and told that he had checked the FI and adjusted it in order to fiwx my stalling issue. After, it was at 1200 but grew gradually to 1800 after a few seconds. Worst than ever.

I have inspected the bike on very side. I broke the fast connector hose during this operation. I did a recondition cycle on my battery. Nothing.

And then ... I did a reset of the FI. It came back to normal (like before the service, with a few stalling but no so much).

And then, then ... I changed the filter for a K&N. Now, it is good, no stalling at all.

But I will put it on a dyno with Tuneboy because I discovered with my TuneBoy that I had an old map in the ECU (Akra map for sure but the 07 one).

FI reset:

• disconnect the battery
  
  
• switch on the engine to be sure to drain evrey capacitor of the ECU
  
  
• wait 10 mn
  
  
• switch off
  
  
• reconnect the battery
  
  
• start the engine without touching anything but the switch button
  
  
• let the engine idle 15mn (no less, no more)
  
  
• don't touch anything the 15 mn
  
  
• switch off
  
  
• switch on, it is done.
  
  

[outlawtigger]

I can't believe no one has mentioned the reluctor ring issue. The flywheel has a press-fit ring that on some bikes had slipped throwing off the timing. There's an updated part that's welded that apparently fixed the problem.

Search on reluctor ring on ktmtalk and you'll find loads of info on the subject.

I am in canada and they also say the reluctor ring is not warranty issue here, even though mine stalls, and I have done most of the items like clutch switch, throttle setting, etc to try and fix.

when I tried to order my own "reluctor" ring part, to do it myself, they told me that if I order that part and have my dealer install it, that will void my warrantee, as "there is NO NEED to do so" according to those who have not seen my bike in person.

obviously, it was just a threat, to stop me purchasing this part, if it fixed my bike, others would use that as proof and demand a recall.

I have access to a superflow dyno and was planning on dynoing and checking before and after.

[jjm525]

How can installing a factory original part void your warranty? That is laughable. Sounds like they still will not really admit there is a stalling issue or FI problem in general???

Has anyone seen exactly what a slipped reluctor ring looks like?

[lowercasee]

I am in canada and they also say the reluctor ring is not warranty issue here, even though mine stalls, and I have done most of the items like clutch switch, throttle setting, etc to try and fix.

when I tried to order my own "reluctor" ring part, to do it myself, they told me that if I order that part and have my dealer install it, that will void my warrantee, as "there is NO NEED to do so" according to those who have not seen my bike in person.

obviously, it was just a threat, to stop me purchasing this part, if it fixed my bike, others would use that as proof and demand a recall.

I have access to a superflow dyno and was planning on dynoing and checking before and after.

Did you check the reluctor ring on yours to see if it has moved at all? From pics I've seen on KTMtalk and SMJ, it's pretty easy to look at and know if it's slipped.

[Albie]

I do not believe it is a mapping issue. There are too many sensors in the FI system that any combination of faults could cause the stalling. It may not even be the FI system at fault. If it was a map (software) issue then everyone would have the problem with that version of map (windows)

While not all of them are mapping issues, the majority are. A lot of people have had their stalling issues fixed by having the Akro map installed. Mine only stalls when I take out the dB reducer insert in my Leo Vinci pipe. With the stock pipe or with the insert in, no stalling. That pretty much points to a lean issue which of course is a MAPPING problem. There's a reason that there are so many tuners out there and custom mapping done. No two bikes are the same. A generic map gets it in the ballpark and that's it.

[outlawtigger]

Did you check the reluctor ring on yours to see if it has moved at all? From pics I've seen on KTMtalk and SMJ, it's pretty easy to look at and know if it's slipped.

just searching/checking for pics now to see what I should be looking for.

I have not looked yet, as I like to have all relevant parts, gaskets, etc on hand before I start any work, as I have no garage, and am working/storing my bike in a back room of my house.

[lowercasee]

/\ Gotcha. I believe that there are pics on the UK KTM forum as well as SMJ and KTM Talk of what to look for.

[sharky34]

just searching/checking for pics now to see what I should be looking for.

I have not looked yet, as I like to have all relevant parts, gaskets, etc on hand before I start any work, as I have no garage, and am working/storing my bike in a back room of my house.

It make sense. My mecanic told me that reluctor was behind the electric wheel and he didn't want to open since he had not the "GO" of KTM Austria.

[HAIKU_DUALSPORT]

I have an 08 690 enduro. I noticed at about 3k miles the gas cap began to leak. Then about 100miles later the bike stopped as if it ran out of gas.

I don't know what's wrong at this point, but I going to have to take it back to the dealer to get checked out.

I'm only guessing, but it could be the fuel pump, or the cap could have caused some kind of air pressure issue???

Does anyone have a suggestion?

[jimmythehog]

"I don't know what's wrong at this point, but I going to have to take it back to the dealer to get checked out.

I'm only guessing, but it could be the fuel pump, or the cap could have caused some kind of air pressure issue???

Does anyone have a suggestion?"

Not sure if its related, but I noticed on my 09 690 E R that the seat was pinching my gas cap vent hose. I noticed it when I bought it, so never had any stalling problems. Not sure if this would do anything, but now when I put the seat on, I make sure the hose is not pinched.

Mine has a LV and running on switch position 3 - so far, only an occasional stall after hard riding, then comming to a quick stop.

[jjm525]

"only an occasional stall after hard riding, then comming to a quick stop."

That is the problem, some get it in everyday stop & go. Seems to get worse for the guys who have it with more miles. Let us know if it gets remedied or worse with miles.

[HAIKU_DUALSPORT]

I was told by the Dealer that the Computer on the 690 just stopped working and would not send a signal to fuel injector.

They are sending me a whole new computer.

I hope they are right!

[Morpheous]

Check this out...(from across the pond)

http://www.ktmforum.co.uk/showthread.php?t=32817

[lowercasee]

Mine has stalled a few times in the past few weeks. Each stall was at a VERY inopportune time and almost cause me to dump it in traffic. I really need to get mine remapped with the Akra map (both maps) and get the Leo on the bike.

[outlawtigger]

happened again today twice, seems like before it goes, it runs lean and rich back and forth like its trying to set the mixture, I am thinking of trying to eliminate the narrow band sensor with a resistor to see if that helps.

[yossinissim]

It has been a wail since I last wrote a few lines in this fantastick forum.

I was just about to sell my bike last week and lucky me I did not!

After spending some fantastic time on it over the weekend, I have decided that the bike doesn't go anywhere!

Since I had the alarm taken out of the bike and also had the Akrapovic fitted, together with the Akra map, the bike runs like a DREAM!! It always fires up strait away, the power is always there and the bike runs very smooth at low speed as well. As I have already said before, it all comes down to the dealer assembling the bike correctly! My dealer is Fowlers of Bristol, their main KTM technician has been looking after KTM's racing bike for the last five years. Therefore, I believe the guy knows what he is talking about.

The reason I wanted to sell the bike was because I got caught speeding on it, three times and I will probably loss my license for a wail ? but who cares, as long as my SMC stays in the house ? (I can assure you this will not happen again!) ?

So, just remember, once the bike had been assembled properly, all the gremlins should go away!?

[jjm525]

I'm still reading FI problems, one guy just got the stalling after 5,ooo miles with none so original setup seems a weak theory for all of them. I've heard/seen it develope & get worse with miles.

I really want to like this bike, a 690r is catching my eye at the shop but I think I'll regret it with the complications of the FI. Another report of disconnected throttle where the engine runs late off the twist and roaming/floating idle causing runaway bike syndrome on downhills would pess me off to no end.

Any updates or higher milage reports? Thanks!

[macutan]

Brought my KTM 690 Duke to the dealer for the 600mi service, and stalled 1 time on the way home,....

took it out today and I almost killed myself in the city (Manhattan) in traffic as this thing kept stalling and then i really had to hit hard on the revs to keep it on... quite a nightmare,... I am really surprised as to how those guys after taking over 400 bucks for the service they didn't test it and gave me a bike in worst state than it was prior to the service,... Anyone knows what is going on?

(i am not at work and still have to ride it back home... another adventure begins... )

macutan

[jjm525]

This is what I'm referring to. How the FFFFF is this still happening??? Its been near 3 years with this engine & FI!!!