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Discussion Starter · #1 ·
Hi all,

Love the site! Have used the forums extensively already to find out a lot of information but would love to have a discussion about the issues I'm facing. I have read a lot of the threads about the 690 issues but get lost with all the mumbo jumbo.

I have a 2013 ktm duke 690 and love verything about it but the reliability. I am not mechanically minded but giving it a crack to try diagnose and fix myself.

Some background of the bike. I live in Brisbane, Australia and use the bike for commuting to and from work plus weekend rides up and down the mountains. In summer it can be very hot and humid. I found the bike runs extremely hot so I had a radiator fan override switch installed.

At 22 386km the rocker cover arm bearing seized. Work that was completed was
Roller rocker on inlet had seized/locked bearing. Drain oil, remove stator cover, remove filters and use magnets to remove debri and flush with oil. Fit new valve spring retainers, got new rockers and reshim valve clearance, refit tensioner. New oil etc and ran beautifully.

Recommend to replace stick coil as it's loose on spark plug. All at a cost of $1300 AUD.

Now the bike is just shy of 24 000km and riding home from work and the engine cut out and the bike no longer starts. Replaced a stick coil (not sure which one was loose). Still not starting. Inspected the spark plugs and one plug looks like it had been smashed (see attached). Replaced spark plug, turned over motor with spark plug attached to the coil and both plugs spark.

Bike still doesn't run :( doesn't even cough to try and start.

Read on here that it might be a fuel pump or fuel filter issue. Tested the fuel pump and still pumping well (allen key pushing the valve in while turning the motor over). But pulled out the pump and filter and found this (see attached) fuel filter full of black soot. I have ordered a new filter so just waiting for that to arrive before I try again.

Would this be the cause as to why the bike isn't starting? And what should I try next? Should I be worried about the spark plug been smashed?

Going to try and get a compression test kit to test the compression. Can someone link me to where I would find what the compression should be?

Other things to note is I believe the oil pressure light illuminated on the instrument panel. I can't remember if it always is before I start the bike?

Thanks in advance for your help and suggestions!
 

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The fuel filter looks bad enough to cause the problem. That said, the plug is a real WTF. I can only think of three ways it could get that way -- a tech smashed it putting it in (in which case it should have run poorly), you smashed after pulling it out (unlikely you wouldn't notice) or the piston hit it. Was it the upper or lower one? I would replace it, remove the other plug and rotate the engine to see if the piston is hitting the plug. If not, see what happens when you replace the filter.
 

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Discussion Starter · #4 ·
The fuel filter looks bad enough to cause the problem. That said, the plug is a real WTF. I can only think of three ways it could get that way -- a tech smashed it putting it in (in which case it should have run poorly), you smashed after pulling it out (unlikely you wouldn't notice) or the piston hit it. Was it the upper or lower one? I would replace it, remove the other plug and rotate the engine to see if the piston is hitting the plug. If not, see what happens when you replace the filter.
Thanks a heap for the reply back!

I have replaced the fuel filter but the bike still won't start (I have charged the battery).

I have also again checked that both spark plugs spark (they are both brand new). Turned the motor over with one spark out and spark jumps about 1cm onto a bolt.

I haven't done a compression test however when a spark plug out and finger over the hole there is good blow feeling and suction.

To answer your question, it was the upper spark that was smashed. I highly doubt it was me when I pulled it out, nor the technician as it was running beautifully after the rebuild.

So not sure where to go next? Would it be the fuel pump? I have read lots of threads and watched videos about the fuel pump and seems to be the next logical part to test and replace.

Does the 2013 duke 690 have those small inline filter? Or just the large inline and screen on the pump?

Thanks heaps for your help! Will keep reading
 

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Fuel, air, ignition.

Can you hear the fuel pump running when you turn it on? When you tested it did you do a pressure test or just check to see if fuel flowed? Insufficient pressure could be the problem .

Did you refuel shortly before the problem. Could be bad gas.

"It cut out." Did it just die or did it lock up? Any noises associated with it dying? (I'm still curious about the plug.) When you turned it over to check for spark, which plug was in -- was it the one with a smashed electrode? Try it with the other plug.

Does it turn over with the starter and not catch or not turn over? If it turns over -- have you opened the airbox and checked for an obstruction? Are there air pulses from the exhaust? Odd but not impossible for an obstruction to occur while riding. Try removing the silencer.

If you have fuel and air and spark, the last possibility is timing. I know squat about TPS and the other devices that time the spark on current engines but they do go bad and sometimes need adjusting. Or so I read on forums.
 

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Oops, forgot. Check valve clearances and operation.
 

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Discussion Starter · #7 ·
Fuel, air, ignition.

Can you hear the fuel pump running when you turn it on? When you tested it did you do a pressure test or just check to see if fuel flowed? Insufficient pressure could be the problem .
Yes, I do believe the I can hear the fuel pump engage for a few seconds when the bike does its start up routine. Goes for a few seconds and stops. And that's correct, i just pushed the valve in and checked that fuel flowed.

Did you refuel shortly before the problem. Could be bad gas.

"It cut out." Did it just die or did it lock up? Any noises associated with it dying? (I'm still curious about the plug.) When you turned it over to check for spark, which plug was in -- was it the one with a smashed electrode? Try it with the other plug.
Not particularly no. Was probably about 5L In the tank.
And just completely lost power. Pulled the clutch in, tried to restart but rolled to a stop.


It was the upper that was smashed and have tested for spark on both spark plugs while one was in and one was out. Currently no damage to the new plug after trying to start the bike 6 times or so.
Does it turn over with the starter and not catch or not turn over? If it turns over -- have you opened the airbox and checked for an obstruction? Are there air pulses from the exhaust? Odd but not impossible for an obstruction to occur while riding. Try removing the silencer.

If you have fuel and air and spark, the last possibility is timing. I know squat about TPS and the other devices that time the spark on current engines but they do go bad and sometimes need adjusting. Or so I read on forums.
It turns over, just never catches, it does 1 tiny puff but that's it. I have not checked the air box and filter but will do that nor have I felt for pressure on the exhaust. I do believe the silencer has already been removed.

Thankyou for getting back to me though. I do really appreciate it and helping where to look next. I am away from the bike for the next 9 days so want to research and buy anything I need before I get back home as after then I have 2 weeks to get it running before I head back to work.

I have been reading these two threads but there is just soo much to digest


Does the 2013 duke 690 have that top hat filter just before the injector? Thanks again
 

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It turns over, just never catches, it does 1 tiny puff but that's it. I have not checked the air box and filter but will do that nor have I felt for pressure on the exhaust. I do believe the silencer has already been removed.
That's consistent with an air/exhaust blockage. No idea on the top hat.
 

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Have you checked that the fuel lines are still attached to the filter ?
Sometimes they'll either pop off if not secured properly or if fuel hose is not rated for EFI (i.e, gravity fed) it might blow.
(ask me how i know..)

The bike will still crank but it won't start if this is the case.
 

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:unsure:......... no update after 5 months, so I am thinking the OP probably sold the bike...... but that spark plug sure looked like it was flattened by a piston :eek:. And that black sludge in the fuel filter - very unusual.........

Maybe the OP might come back and let us know what went wrong with the 690?
 

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I’m in the same boat as you looks like you’ve had a team of experts to help you troubleshoot your issues the way you describe everything is exactly what I’m going through. Please let us know what was the outcome.
 
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