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Author Topic: Project CB690 (KTM 690 engine in a CB550f frame)  (Read 20938 times)

Offline irk miller

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #180 on: May 07, 2019, 13:54:50 »
You need a factory service manual.  No sense in determining drainage or the right size of the pot without checking specs in the manual first.

Offline trek97

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #181 on: May 08, 2019, 08:56:50 »
You need a factory service manual.  No sense in determining drainage or the right size of the pot without checking specs in the manual first.

+1. ha

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #182 on: May 08, 2019, 17:13:45 »
Front fender arrived today. I will NOT place the fender that high off the tire, I just stuck some foam under there to take a picture before being called in for dinner. I was just trying to see how the radius matched. I'll have a think about how to mount the fender, it will be a challenge. You can see from the second picture that there are only 3 holes on the lower fork leg where a mount can be placed, and they are all kind of close together.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #183 on: May 18, 2019, 17:27:44 »
Inside of the fuel pump, in case you're interested. I had to determine which of the terminals was positive so I didn't hook up the pump to run backwards.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #184 on: May 18, 2019, 17:42:40 »
Big day! The bike runs. I put the wiring harness in temporarily, hooked the fuel pump up to a remote reservoir, installed all accessories and sub-harnesses, and made it run. I just wanted a baseline before I start cutting the wiring harness. The harness is not too bad, only a few things need to be relocated. One of the computers can live under the tank, that is good. The fuse box must be relocated about 40cm, the starter relay 45cm, and a few odds and ends need to be moved as well. Those are the big ones, though. I will start that soon.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #185 on: May 18, 2019, 17:43:56 »
Don't you worry about the muffler, I swear it's only temporary.

Offline Luugo86

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #186 on: May 18, 2019, 21:11:20 »
 This is a cool project man, I'm in.
Live to Die, Die to Live

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #187 on: May 19, 2019, 13:20:47 »
Got into the wire harness today. Just did some planning and cutting in preparation for the relocating. I found a few more things to relocate, like the ambient air pressure sensor, blinker relay, and diode. These are currently located in the headlight shell, but I will have a lot less space than the stock configuration due to using a 7" round headlight. So I will relocate them under the seat. I will use Spec 44, tin plated copper wire to do any replacement or repairs. It's the good stuff. I will also solder in two different resistors, in place of the Secondary Air System solenoid and the fuel evap solenoid. I've read about these on 690 forums. Interestingly, my bike had both systems removed, but the plugs were just left empty, no resistors or dongles or anything, and the FI light was not on. Maybe it had been remapped? When the bike is remapped you can just delete the part of the program that uses those systems, maybe that is what has happened. I will install the resistors anyway. This bike also has a gear position sensor for N, 2, and 3. When in 2nd and 3rd gear, evidently for noise reduction, the map takes (supposedly) 20% power away. My bike had this system disabled. I will enable it. If for some reason I feel like I need more power in 2nd or 3rd, maybe I will do a back-to-back test with the old seat-of-the-pants dynamometer.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #188 on: Jun 03, 2019, 17:06:39 »
The harness work is in progress in these pictures. The necessary bits have been relocated, just needs tidying up.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #189 on: Jun 03, 2019, 17:09:47 »
All tidied at this point. The harness is now back on the bike and going through testing. It fires up, no FI light, so far so good. Just have to test all the safety systems and switches, horn, lights, etc. Then I will remove the harness again and wrap it. Then I can finish mounting all the electrical bits like the solenoid, computers, sensors etc.