Valve clearance. Yea it is noisy. I think the rocker arm is done. Will order one tomorrow.Originally Posted by DRxDR
Valve clearance. Yea it is noisy. I think the rocker arm is done. Will order one tomorrow.
KTM 2008 690Duke
2007 CRF150R
KTM 2000 DUKE II
Yamaha TTR 150
A .030" wear on the rocker with only 17k miles is premature wear and you'll find out if it was the rocker versus the valve/seat when you install the new rocker.
Also, why only on the intake? wayne
Yea no crap! If it was the valve seat then it would be tight not loose. Could also be the valve springs are shot but I doubt both went bad at the same time but you never know. As for only the intake I have no idea. What is scary is my duke II gave out around the same mileage. But for a whole other reason. I have yet to put 20,000 miles on a KTM.
KTM 2008 690Duke
2007 CRF150R
KTM 2000 DUKE II
Yamaha TTR 150
Gravity I understand your reluctance to use Tuneboy, especially with Waynes notorious lack of customer service, however with any modification to the bike as far as exhaust or airbox goes then you are going to have to get some more fuel in there and as Tuneboy is the only system that has been tried and tested on our bikes and the only one that I know of that writes to the ECU and can disable the O2 sensor, then if you don't want your bike to run even leaner, then Tuneboy is the only way to go. For me the main worry was finding a Dyno and tuner that knew the program and knew what they were doing, this is far more of an issue than getting hold of Wayne. It sounds like you have found a good guy and if he knows and likes the program then you should be home and dry. Also Wayne seems to respond best to fellow tuners so if you have problems your man might have better luck talking to Wayne than you might. However there are plenty of helpful people on here can help sort getting the annoying interface questions answered if you experience any. Good luck and let me know what you decide to do.
Update!!
Well I spoke too soon! fucking KTM piece of shit! Rocker arm failed! The bearing on the cam seized up and ate the cam! Looks like about 400 bucks of damage but I am so sick of this shit! Too bad I didn't do that big bore cause I will be half way there to an install. Plus I got to buy a cam now!
KTM 2008 690Duke
2007 CRF150R
KTM 2000 DUKE II
Yamaha TTR 150
From another source,(ktmforums.com) a pertinent conversation....(Rocker problem, sounds exactly the same) Hope this reference helps!
OKAY; I picked up the Duke tonight......it is quiet as a KTM can be and runs like a scalded dog! I looked at the parts that came off of the bike......roller bearing on one rocker assembly was loose and rattling; obviously what was causing the internal noise. The bearing on the other rocker was pitted. The bad bearing had scored the camshaft where it contacted. It appears that there was a bad batch of roller bearings. Dealer (and KTM) replaced both rocker assemblies, the camshaft, and the bearings that the camshaft rides in. I didn't get a case number, but the dealer said that he was also looking at an SM690 with similar problems.
ama (Miles Albertson)
Quote:
Originally Posted by Morpheous
Man Im really sorry to hear that. Bummer. At least KTM is fixing it for you! If you can try to get a case number for the rest of us to reference to KTM NA if we find the same situation on our Dukes. Mine is going in for its 6000 mile valve check and I want them to look specifically at my rockers. I hope you get your bike bake SOon. With all the akro and fuel map it should scream. -Michal
Quote:
Originally Posted by ama
My dealer is Mike's Cycle Shop, a long-time KTM dealer just south of Ocala, FL. The bike is still there; current story is that they had to overnight a bearing puller from KTM specifically for the 690 motor that they didn't have. They are now saying that I might get the Duke back tomorrow at the end of the day. I'm getting really frustrated. I't been over a month since I dropped it off.
ama
Quote:
Originally Posted by Morpheous
Hey, any update on your warranty work situation on the rockers? thanks, (I pretty sure I have the same issue) Who is your dealer? Do you have a case number with KTM? any info would be appreciated. -Michal
Last edited by Morpheous; 03-10-2010 at 08:23 PM.
2008 Duke 690 (19,000mi)
Failed rocker bearing. Now it all sounds reasonable because I just couldn't believe that the rocker casting or it's wear point on the valve bucket could have caused a .30" wear/gap condition. Is there anyway of testing or foreseeing a problem with the bearings? Such as a manufacturers stamp or number etched into them or early wear/runout? Could it be due to a lubrication problem or over-rev on a regular basis? wayne
Yea I am kicking myself for missing that. It showed zero signs of wear marks. I should have measured the dia of both rocker arms. Trust me I am kicking myself over this. I never over rev the bike. I do ride it hard but I take care of it. I change the oil every 2000 miles and there was not a lube issue. I am working with a dealer right now trying to resolve this but I might just order the parts anyway. I mean whats 300 bucks when you own a KTM?
KTM 2008 690Duke
2007 CRF150R
KTM 2000 DUKE II
Yamaha TTR 150
If this has occurred across models (SMC/Duke) on the 690 LC4, KTM should have a record of it. I would call the dealer mentioned in my post above and try to get some case numbers......It should be warranty.
2008 Duke 690 (19,000mi)
So I've pulled the trigger and ordered Tuneboy. Plan to try some of their maps first to see if it solves stalling issue. This arvo I took the bike for the first proper spin since changing the insert around from low noise to 'high flow'. Holy crap - the bike nearly rips my arms off. I am staggered at how much harder it pulls. The difference between stock and this is HUGE. Anyone who says it dosnt make a big difference .... well I just don't know. Perhaps with an unmodified air box the differnce isn't as great. Once TuneBoy is installed and map loaded - if the bike is running good I'll do a power run to see how much more it's making. Previous mods on other bikes lead me to expect at least 3hp or more. Seriously, for those considering this pipe (stalling issue notwithstanding) the improvement is not just in noise (yes there is plenty of that), performace is greatly improved.
That didn't take long....
1997 TL1000s
2002 Ktm 300 mxc
2008 690 Duke
2008 530 xcrw
btw, why not the GPR tuner? Seems similar to what dynojet would build and maybe better customer service than Tuneboy?
Dunno, no experiece, but they seem to offer a product at a decent price.
1997 TL1000s
2002 Ktm 300 mxc
2008 690 Duke
2008 530 xcrw
Lol - was waiting for this. What can I tell you - I just can't leave my toys alone, it's a sickness. As it happened, I was given some cash to blow on a present to myself and all I could think of at the time was a pipe. I had a custom made pipe a while back but had to remove it due to complaints in my building. Having moved and having sold it, I couldn't help trying again. As dumb as it may sound, I was actually expecing to regret it / be disappointed but I'm not, I'm happy (cept for the stalling).
Has anyone found the akra map and exhaust not to work well?
I went this route. Haven't installed them yet. Need to get 600mi on first.
This is my 3rd SM. First was a Husky SM610 (carb) after lots of
different setups I took it to a local tuner and he got it right.
Rode the bike about 6K miles no problem.
Next was a Aprilia SXV 550 (FI) After a couple of exhausts, air box
mods and filters the same tuner got it working well. Minimal increase
in power over stock as he suspected. I ended up going the Power
Commander route on the Aprilia as thats what the tuner used and likes.
We discussed the TuneBoy software and although it was better software it was much more difficult for him to work with. He said after
each map change he would have to power cycle the bike and software
making tuning very slow. Resulting in a much higher cost to me.
So this time I went for the KTM solution. I will bring to the same tuner
just to get a HP reading and to check air fuel ratio.
I'll post the results.
glad your happy with it,if after spending all that $$$$ i had a loud STALLING bike i"d be pissed
Well I have a bike that actually sounds like it looks - a little mean. Loud yes, but not unpleasant. As for the stalling - that was something I knew was a risk before I went ahead so I'm neither surprised nor pissed. Some people get the stalling - some don't. Back in the day when I bought this thing I said I wouldnt mod it like I have every other bike Ive owned. That didn't last long. Like I said - it's a sickness. But once I get the fuelling sorted - I think i will be very happy because even now - the bike goes like stink!glad your happy with it,if after spending all that $$$$ i had a loud STALLING bike i"d be pissed
Quasi thread jack
Seems everyone with a duke is in here or at least very likely to be reading the thread from time to time.
Has anyone with a duke also rode a Triumph Street Triple? I would be interested to hear their thoughts and opinons on the differences between the two.
It would be used as a weekday comuter and a weekend toy ocasional highway trips of maybee a couple of hours at most.
Would the triple be better suited to carrying a passenger?
For the price of a new duke it would be the Street Triple R.
Completely different type of motorcycle..but, you can do anything with any bike. Riding two up will put more demands on the rear suspension so the R with damping adjust ability would be better.(Unfortunately you need more spring rate usually) The Powerband is going to feel completely different compared to a single cyl duke. Multi cylinder engine is smoother and will handle the two up riding better over time. (Ie.. Crank bearing loads) For what you described as your uses, the Two up riding makes the case for the S3. Other wise the Duke is a Superbe commuter and weekend twisty fun machine that will also roll down the hwy for as long as you can...
2008 Duke 690 (19,000mi)
I owned a Street Triple R and I rode the Duke 690, now I have a KTM 990 SM. I think the Street is the best choice for you, it's much smoother so more comfortable for the passager and has a wider powerband so you can ride very lazy. With the Duke you're always shifting trough the gears while you can put the Street in 5th gear and keep it there all day if you want. The Street engine is so smooth! and the suspension of the R version is the best I've ever rode, the Nissin radial brakes are also great!
Remus with stock map
Has anyone fitted Remus muffler with stock map?
I spoke to my local Remus dealer and he said that the EEC-pipe (with catalysator) is designed to work with standard ecu. No remapping needed...
I'm talking about this product:
# HexaCone, slip on incl. Cat, Stainless Steel, EEC,
# Article#: 154682 655108
# Article: KTM - 690 Duke from 08 - 48 kW
Anybody here with this setup? Any issues...?
Integrated tail light for the Duke 690
Fantastic new integrated tail light for the Duke 690 and 990R SD from Bike Monkey.
Here is my review with a video.
Drop Carl at Bike Monkey a mail as I'm sure he is now taking pre-orders.
http://vimeo.com/10334575
Edit/Delete Message
I came across some threads a while back of some guys who'd fitted the Remus. No issues were reported. Apparently the pipe is well made and is not too loud. As per the site, gains are 1.8hp which would be barely perceptable.Has anyone fitted Remus muffler with stock map?
I spoke to my local Remus dealer and he said that the EEC-pipe (with catalysator) is designed to work with standard ecu. No remapping needed...
I'm talking about this product:
# HexaCone, slip on incl. Cat, Stainless Steel, EEC,
# Article#: 154682 655108
# Article: KTM - 690 Duke from 08 - 48 kW
Anybody here with this setup? Any issues...?
Well Update on the Rocker arm issue. I put the Duke all back together and she runs good. Zero valve train noise now. I suggest anyone with a 690 check your rocker arms or just replace them is any looseness is found when doing a valve adjustment. Yes it is about 120 for the parts but it is easy.
KTM 2008 690Duke
2007 CRF150R
KTM 2000 DUKE II
Yamaha TTR 150
Thanks for the info.
I don't care so much about the power gain. My previous bikes were DUKE II with full Acra, Ducati Monster 620 and S4, both with full Termi and my other bike is a 40 years old Harley with drag pipes, so I hardly heard my new bike was even running...
Love the bike, especially when it doesn't sound like a lawnmover anymore...
dodge: Did you see the post by "tattoo" over at the UK site regarding replacing just the pin and bearing versus the entire rocker arm?
FROM THE UK SITE:
mr.tattoo
Posts 14,094
Blog Entries1 did the bearings sieze on the rockers? ive seen this a feew times now, a few guys off heres bikes have done that ive fixed. bearing siezed then ruined the cam, you can buy just the bearings and pins from ktm pretty cheap
***Edit***
May have to disregard the pin and bearing method since it is for the 640 motor and not sure if it is even possible on the 690. w
Last edited by DRxDR; 03-26-2010 at 07:50 PM. Reason: 640 LC4 vs 690
Joined the club
Joined the club this morning. Its so much fun, can't wait to get the pipe on and remapped
So is Scotts the only option for a steering stabilizer/damper for the Duke? Would like to pick one up, even though the Duke is perfect.
So it's been quite the ordeal over the last few weeks...
I eventually got the tuneboy for my bike to sort out the stalling issues created by the fitment of the FMF pipe. On the very day that I loaded the tuneboy software - the engine blew up. Of course my initial reaction was that it HAD to be because of the tuneboy software. But, I was not going to start blaming anyone (or posting anything on the web) till I knew exactly what had happened.
Turns out that it was just a stressful coincidence. My bike had suffered from a seized rocker arm roller bearing which has in turn destroyed the cam, cracked the valve cover and basically destroyed the whole top end. This was a mechanical issue and had nothing to do with Tuneboy. I had noticed my bike becoming more and more rattley over the last few months but as with anything that gets worse slowly - I hadn't reallt paid too much attention to it. On the day it stopped - the engine started to rattle like a tin can full of marbles. Then it died.
My dealer wanted nothing to do with it and was the rudest d*ck I have ever dealt with. So I went to the KTM importer directly who were increadibly professional and appologetic for the way the dealer behaved. After rapping him hard over the knuckles, and it was fixed free of charge under warranty. The bike has only 5000kms on it and has had two oil changes since new. Be warned - this is becoming more and more common and is clearly and issues with the LC4 engine. If you're bike is making noises you think it shouldn't - it's probably on it's way to failure.
After getting the bike back, I tried again with the Tuneboy software loading the sports pipe map for the bike. Wow. Not only has my stalling issue gone but the bike pulls really really hard right off idle. In second gear I can snap the throttle shut and wack it open and the front comes right up. I can clutch it up easily in third on flat ground.
So far so good. Now to get it custom mapped...
Last edited by gravityfreak; 04-11-2010 at 08:29 PM.
i saw a duke last week and am in hard love for it.
that is the moto.
what would it take for other manufacturers to follow suit.
suzuki had a Goose 650- a thumper naked 650 ina GS500 looking chassis.
it was tits...but this is just wicked awesome so- wicked.
_09 Suzuki 400SM_
1979 CB750K-
Side car with no bike attached
lost but not forgotten:1999 Honda CBR 919, 1996 Suzuki gs500e, 2005 Suzuki SV 650,
Would a damper for a 690 SMC work on the Duke? If so I thought I saw a GPR damper on eBay for the 690 SMCs.
Hi there,
I also have an 08 Duke 690, mine has over 10,000 kms. Does anyone know if the bearing issue is related to a batch of bearings or if it is a design fault. I am just wondering if it would be worth while replacing mine now as the bike is no longer under warranty.
I also have the Apex pipe, K&N Filter and Tuneboy map. All of these are great but the biggest gain from this bike so far has been fitting a 75 spring. Going from 70 to 75 doesn't sound like much but it certainly improves the handling. I have also had the shock revalved to suit. If you are a similar weight to me (just over 95kgs) it is a must do.
Mike.
Mike, is there an issue with bearings? Other than gravityfreak, I haven't heard of of very many 690 motors failing. I wouldn't call it a design failure until we see many, many more..but that's me. At 6k miles I wouldn't be worrying about it so much, most problems you would see will have already occured. Mine's getting close to 11k, absolutely trouble free.
Agree about the springs. Very hard to find, but worth it, and the best upgrade to be done imop. I thought about the pipe/etc for a few more hp, but decided to get a 530 instead. those have WAY more issues as a first year model than the Duke...and you really appreciate the counterbalancer on the 690 after getting off the 530. Both great bikes though.
1997 TL1000s
2002 Ktm 300 mxc
2008 690 Duke
2008 530 xcrw
where did you guys find heavier springs?
I tried to see if they'ed work, but I doubt it. From the looks of it the mounting points are completely different between the duke and smc.
If im not mistaken, aren't scotts stabilizers able to be switched from one bike to another, just using different mounts? Wanted to pick up stabilizers for my 675 and my duke, might as well get one with 2 mounts, and save a shitload of cash!
After 2 months of searching, Scott at Factory Connection was able to find ONE rear spring alternative, and TWO fork spring alternatives. Took 6 weeks to arrive from Europe.
that was last year, no idea if there are more current offerings.
every local suspension shop said the same things prior, "we've got no idea, bring it in"....
Seriously, move a damper from different bikes? wow....seriously a pita.
1997 TL1000s
2002 Ktm 300 mxc
2008 690 Duke
2008 530 xcrw
KTM-Parts.com
Here is the part number & description 91110013S SPRING 185MM 75N/MM.
You may not find it on their website but if you send them an email they can order it for you.
I am in Australia and it took about 6 weeks for the spring to arrive. Most of my wait was because they special order it from KTM & it is shipped to them from europe.
Mike.
How so? It's two bolts? Would take about a minute to do, (add another 20 sec for torque specs). I'd rather spend the extra minute and a half working on my bikes, than spend another $325 to have two dampers that do the exact same thing. And besides, can't use them both at the same time. Not that much of a pain in the ass.
Is anyone running the airbox mod with the stock exhaust? I have no intention of replacing the pipe, but im having some stalling issues so wondering if the airbox mod may help.
Well now thats 4 690 motors that have had the roller rocker arm bearing go bad. I would say that is a problem.
KTM 2008 690Duke
2007 CRF150R
KTM 2000 DUKE II
Yamaha TTR 150
Yes I have done this. If you are having stalling issues - opening your airbox is likely to make it worse as the stalling seems to be caused by a lean condition. Have you done the 15 minute idle / ecu reset ?
hey im new to all this crap. i bought up a 09 duke 690 and just got a fmf apex slipon. . my question is .. now i hear i could be fucking up my motor cuz i dont have it tuned(tuneboy) yet or dyno' done with the new exhaust?? i hope not i put like 200 miles on it with the new pipe. i noticed i losed 15 mph on top end but gained on bottem. i havent noticed it running bad or sounding bad. and what can i get done to get the most of the bike like this tuneboy i hear about? and can you do it urself.? and what about ppl drilling holes in your air box? and with a new air filter will i have to get it re tuned? sorry but i dont know shit lol and need to learn.. thanks rick
Hi Rick,
Welcome to Dukeland. The bad news is that by now you have completely destroyed your engine. You are in for several thousand dollars worth of damage and you have voided your warranty.
Just kidding mate - relax - you'll give yourself a ulcer.
If all you have done is fit the Apex pipe to your bike - you are FINE. If you're bike is running dangeroursly lean - you'd be getting the well documented stalling issue which you have not mentioned. If you want to be 100% safe - take it to a place that has a dyno and get them to check the air fuel ratio but as I have said, if you've done no other mods you really don't need to. However, if you wish to extract more performance from the exhaust you can get your KTM dealer to load the Akrapovic exhaust map. Cost is minimal.
If you start playing with the airbox in an attampt to get more power out of the bike (which you can) - you will start to run into the danger zone of running your bike dangerously lean. Then you will need to correct that and the only way currently available to us is by purchasing the Tuneboy software. This is a DIY solution as you can simply download the sports pipe map yourself. I have done this and it solved all my staling issues and the bike runs strong. That is a further $500 investment.
The final stage of tuning is to have a dyno centre who is familiar with Tuneboy to custom tune your bike to run well with whatever modifications you make to the exhaust or airbox. This adds further expense and can be difficult as Tuneboy is still relatively unknown.
Can't get it to idle long enough, ive got it up to 14 before, then it just cuts out. Even when out riding you can hear it trying to stall when at a standstill. Ive done the 15 minute idle before with no problems, but this year its not liking it.
On the SMC damper question: The SMC damper will be longer (physically and in its stroke) than a Duke damper, so it will change the steering geo significantly, it may also cause the chain to rub on the top of the swingarm. ?
2008 Duke 690 (19,000mi)
http://www.ktmforums.com/forums/duke...isy-motor.html
2008 Duke 690 (19,000mi)
Maybe I am paranoid but I have more than 10,000 kms on my Duke and I don't want an expensive repair bill. I would rather pay the $150 to replace the rocker arms and shafts.
2 new rocker shafts and 2 new rocker arms are now on order.
Last edited by M_450; 04-15-2010 at 06:08 AM.
Just racked up the first 1000kms and had the bike in for a service, had the Akra map loaded to go with the FMF, K&N and snorkel removal I'd done, first impressions is its alot easier to get off the line with the factory gearing, not sure if its much faster but the front does get lighter in first on the throttle, its no wheelie monster compared to standard but still have the 15t to go on but wanted to map it first, all in all I'd say its worth doing just for the better launching.
My understanding is the Akra map removes the 2/3 restriction also, is that correct? Also I did wonder if anyone with a pipe, k&n, akra map had done the airbox mod and dyno'd it to see if its leaning out, would look at doing it but not really interested going down that path if its going to require a tuneboy.
So whats the maintenance intervals like on these? Really considering getting one.....
2008 Yamaha WR250X, 2007 Kawi Z1000(FOR SALE), 2003 Kawi ZX6R, 2005 Xtreme CR107 Pit Pro(FOR SALE).
So I looked online at the owners manual. Looks like 600 mile service then everything else is every 3000 miles. 6000 for valve check. This sound right for the 690 motor?
2008 Yamaha WR250X, 2007 Kawi Z1000(FOR SALE), 2003 Kawi ZX6R, 2005 Xtreme CR107 Pit Pro(FOR SALE).
Sounds right.
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