KTM 690 Problems – Our List of Common Issues and Solutions for Them

A renowned European brand, KTM has enjoyed an immaculate reputation in recent years. It should come as no surprise then that the KTM 690 lives up to the high technological standard they set. As a luxury model, it is certainly costlier than your average bike.

But the quality more than makes up for the exorbitant price - or so you thought until it started misbehaving. From a permanently lit engine light to severe stalling issues, we're going to tell you some of the most common problems with this model and their respective solutions. 

Faulty Clutch Seal

The first issue on our list is not one you can influence as it happened during the manufacturing procedure. Many KTM models were assembled with a broken clutch seal, which ultimately led to a worldwide recall of these faulty motorcycles. 

The main reason why this was such a huge safety risk was that the clutch refused to disengage. This caused the bike to jump forth a little whenever the clutch was operated. 

If you've bought your KTM 690 only recently, then you have nothing to worry about.

Loose Camshaft Sprocket Bolts

As their name suggests, these bolts hold the camshaft in place. This is important since the camshaft must be perfectly synchronized with the crankshaft for smooth engine operation.

KTM has made a blunder with some of their models, which were manufactured with poor bolts. The KTM 690 is one of them. Plenty of owners have complained about losing these bolts whilst driving. The luckier ones who managed to salvage the bolts had to use Loctite so that they held in place. 

A new motorcycle should not come with such a serious problem. Rather than attempting to fix it on your own, we suggest taking it to the dealership and having them install the proper bolts. 

Faulty Fuel Pump

A fuel pump moves fuel from the tank to the engine. It is a vital device given that most modern bikes can't rely on gravity alone for efficient fuel distribution. Thus, a weak pump will not deliver enough fuel to the combustion chamber, resulting in poorer performance.

One of the telltale signs of a failing pump is ignition problems. If your KTM has difficulties with starting or won't start at all, the pump might be to blame. However, make sure you check for other symptoms to get the most accurate diagnosis. 

In case your bike starts just fine, but you have trouble with acceleration, your fuel pump might be lagging behind. Insufficient fuel supply might also lead to misfiring. This happens when one engine cylinder produces less energy, resulting in a loss of steady rhythm. If the pump can't keep up with the fuel demand at all, stalling might also occur. 

The last common symptom is a whining noise coming from your pump. 

Naturally, even the fuel pump has an expected lifespan and it won't last indefinitely. However, owners of this model have complained about their pumps failing below 8000 miles. That's way too early for it to start malfunctioning. Moreover, repairs of this device call for a mechanical savvy that you are unlikely to possess. Visiting a professional might be unavoidable. 

Traction Control Malfunctioning

Sometimes called Electronic Stability Control, traction control is a mechanism implemented to enhance the safety of your motorcycle. It facilitates acceleration, braking, and steering. Though professional bikers might manage without it, the ones new to the craft can certainly appreciate it. It comes in especially handy when riding over rough or slippery terrain. 

Traction Control steps in whenever one of your bike wheels starts spinning faster than the other one. To offset this speed disparity, the system slows down the faster one so that control is regained. By doing so, the risk of skidding is greatly reduced. 

Since the implementation of Traction Control into motorbikes is still in its infant stages, it is featured on mainly luxury models. The KTM 690 is one such model. However, many owners have reported that the system tends to shut down on its own. Little good does it do to possess such state-of-the-art technology when it doesn't even work. 

One way to fix this issue is by stopping your KTM and holding the TC button for 5 seconds. Make sure you press it firmly as it is not very sensitive. When it's turned off, your Traction Control is enabled, and vice versa. This can be misleading, so keep it in mind. If the button is completely unresponsive, there's nothing else you can do other than visit a professional. 

Rocker Arm Failure

If you have little to no mechanical background, then you've probably never heard of this term. An indispensable engine component, a rocker arm transmits motion from the camshaft to the intake and exhaust valves. 

These valves must operate harmoniously. Desynchronized, they negatively impact your bike's performance. When the intake valve closes too early, there is not enough air for combustion. Since insufficient fuel is burned, you will notice the engine's performance drop. 

On the other hand, if the exhaust valve opens too early, fuel might be ejected into the exhaust pipe. While this also results in a performance drop, it might also cause backfiring. The fuel might be ignited inside the exhaust pipe, resulting in an explosive sound. If it happens too often, your KTM will face irreparable damage. 

In addition to deteriorating performance, there are other symptoms associated with a faulty rocker arm. Random stalling is one of them. Eventually, you might be unable to start your KTM at all.

Other common signs are odd clicking noises coming from the engine. This occurs when the arm grinds on other metallic components in the engine. Over time, the friction will damage it.

Of course, your engine light will turn on in case there's a malfunction. However, it can't pinpoint the exact component that is to blame. Moreover, the KTM 690 engine light has been known to act up, so this might not help you much. 

We mention these symptoms because the early KTM 690 models (2013 - 2014) sported unreliable pins in their rocker arms. If you bought one of these models and experience the signs above, consider upgrading your rocker arm to the 2015 model. Few issues are known about it. Before you do so, consult a mechanic to find out if your KTM is compatible with the upgrade.

Rev limiter Malfunctioning

The rev-limiter is the part of your engine designed to protect your engine from damage. True to its name, it achieves this by limiting the maximum reachable RPM.

However, this device is known to act up in KTM 690 models. Misreading your actual RPM might stop you from reaching higher revs even when it's not dangerous. As an avid bike rider, you likely haven't bought the KTM to merry-go-round around the country, so this speed limit is definitely an issue. 

As far as fixing this is concerned, you will need to pay a visit to your dealership.

Dashboard Engine Light Turns on Randomly

Some owners of the KTM 690 Enduro variant have noticed their Engine light turning on even when there is no malfunction. While the most damage this can do is deepen your paranoia and anxiety, you'd expect such an expensive brand to prevent such petty problems from happening.

This issue tends to start after you tinker on your bike for the first time. To prevent it from happening, never turn on the key or wake the display on your KTM with the sensor detached. 

In case it's already happened, turn your bike on and off three or more times. The system will detect that there is no problem with the engine eventually. Should the light keep glowing stubbornly no matter how many times you do this, consider visiting a mechanic. There might be actual problems with your engine. 

Throttle issues

Also common for the Enduro variant, this issue is related to poorly calibrated throttle. This engine part is responsible for managing the correct air/fuel ratio in the combustion chamber. As you probably know, you control it by twisting your right hand. 

When the throttle's faulty, your engine will experience stalling. Some riders of KTM 690 have complained about frequent stalling, especially in scorching weather. This issue tends to worsen when driving over hazardous terrain. The throttle refuses to rev over certain RPM, which causes the engine to stall.

The temporary solution would be to stay in the lower gears when riding in these conditions. For a permanent fix, you will have to recalibrate the throttle. This requires some mechanical skill and does not guarantee that the issue won't return. Sadly, seeing a professional mechanic might be the best decision here. 

Conclusion

To sum up, KTM 690 is considered a reliable model. However, there are some issues commonly associated with it. They range from innocent ones such as a permanently turned-on engine light to dangerous ones such as frequent stalling. Minor problems can easily be fixed yourself, but technologically advanced issues might call for professional assistance.