KTM 690 throttle body idle issues explained and fixed.

A detailed explanation of the KTM690 throttle body problems that cause bad and inconsistent idle, cutting out and poor low throttle response. w
With an explanation of how to fix.
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[@cooky03]

Nice content Jim. Simply explained without being patronising. If only all bike fixing content could be like this 👏🏻👏🏻

[@garypatterson2241]

Great to see you back Jim . Your a star

[@00Munki]

Glad you back! Missed your videos.

[@petermosdell580]

Welcome back Jim 👍

[@marklupton2064]

Always enjoy the vids 👍

[@sabamacx]

Thanks for the charger recommendation, really nice kit.

[@mohamadredzamustafa330]

tq sir. got the same problem with my duke 3. been in workshop more than 1 year already. will try to do the same

[@295walk]

I dont own a bike or licence but love this after watching 2 videos . love the tech , the bikes but yourself equally . Great stuff thanks .

[@daviddanielstephenson2833]

Nice diagnostic job Jim, some stepper motors are very sensitive, the more steps they are tuned to the driver with the more sensitive they become. I have come across these plastic gears before, when they get heated they can shrink, as if they have an injection memory, this is probably why they changed it for a much better fitting metal version.

[@davidtenorio9429]

That was really amazing my friend! Thank you!

[@DanMotoLife]

Nice work, thanks for a lesson 😊

[@carlhansen8668]

Great how you found that fault👍 or do you have access to tech data with common faults? Great to see your videos again 😎

[@taswr]

Yes more content like this 👍🏻

[@510TITAN22]

Thanx for all the info

[@RaulMotoADV]

Thanks for sharing, and i will go to Patreon. 🤟🏽

[@nicoverduin]

i can follow you're explanicion in totall Jim....is there a replacement wheel for the plastic one?.i think you can't do this without any electronic measurments

[@sjreidkiwi]

Legend. Thankyou for the amazing informative video, interesting that TPS needs to be disconnected to start… TEXA doesn’t mention anything about that in the diag instructions. Love TEXA, but little things like this can trip you up easy if you don’t now.

[@maximilijan77]

Thanks!

[@jimmcinnes8922]

Hi Jim, a few mentions about metal gears ? can you maybe reply and tell us all of you know of anyway to get a hold of metal gear replacements. Thanks

[@lunarticpickle]

Hello Jim, how are you? I’m new to this page and I’ve been looking for you for a little while. Thanks for the explanation here, I’m just wondering if you live in Ontario Canada by chance? As I do need the tps setup!

[@hlpang1075]

Its amazing how you know so much about so many bikes!

[@SuperbikeSurgeryTV]

The problem is that's all I know. Just ask my wife!

[@hlpang1075]

@@SuperbikeSurgeryTV 🤣 Will you be so kind to show us how to remove and install rubber grommets? Especially the really hard ones n exhaust brackets 🙏

[@__jake46]

Hi great video with alot of information! Would this be the same process for a 690 smc 2011? Ive got pretty much same tick over issues and keeps cutting out at lights. Been told i need a new throttle body but im hoping this could work? If someone could let me know be very appropriated 🙏

[@x1324554]

Hi may I ask the panasonic toughpad fz-g1 is which version ? MK4 or MK5 ? Are there any special features available?

[@owh4756]

Hi,I got a problem when adjusting the emergency position.The fuse cover on the adjuster stuck with the nut.Any idea how can I remove the cover so I can adjust it.

[@firestorm755]

Great info but does highlight the fact that you need the relevant computers and software to work on these bikes.

[@ronanrogers4127]

You can recalibrate Keihin TPS using a multimeter…all his software is doing is reading the current and displaying it as being in the correct range (ie green). But if you have the workshop manual it’ll tell you the values you need and you can do it with a multimeter off eBay. It’s not hard at all.

[@omarbendoula152]

@@ronanrogers4127can you give the value of both of tps sensor I have ktm 690 smR 2008 and I have a lot of admission problem those days and thank you

[@paultanton4307]

Welcome back Jim,another interesting video thanks,i have a question for you,youtube is a veritable goldmine for many subjects, and Motorcycles are one of my passions,with absolutely no disrespect to other mechanically minded content providers you are one of two i would watch first for quality,have you ever rubbed shoulders so to speak with Allen Millyard ?.

[@SuperbikeSurgeryTV]

No, but I'd love to sit down with him and have a brew, very interesting guy 👍

[@paultanton4307]

@@SuperbikeSurgeryTV Yes im sure you would both have a lot to chat about 😀

[@ekspatriat]

An why oh why can't KTM admit this issue and supply the metal gear as a part?

[@iant1891]

What if i only replace the plastic throttle wheel thing? Do i still need the diagnostics tool

[@nbtv066]

Dear Jim , I'm a bit confused.KTM's repair manual say have to disconnected throttle motor before adjustment procedure.I followed but can not completed adjustment.(I also use TEXA for adjustment.) You say disconnected TPS connector before adjustment procedure.And you can completed adjustment.I didn't try your way yet.But I just like to ask you , did you try to follow they repair manual by disconnected throttle motor?

[@xUnWeLcOm3Dx]

Hello I have a problem and I was hoping If it would be possible to communicate with you and explain maybe you can help me ...

[@paulwhite1977]

Do you know if I buy a replacement throttle body would it come with a metal gear or a plastic one, I've been quoted £1200, cant see how its £500 labor for the job as I've pulled mine out in 30 mins ( on the smc 690)

[@OwainapDewi]

Jim I have a very similar problem on my RE Himalayan with a Keihin EFI system I have been trying to fix for months, the throttle body looks quite different to this one though, doesn't seem to be any cover with gears behind it or anything, a lot more simple, any ideas of what I could do to solve my problem?

[@SuperbikeSurgeryTV]

Thanks for your comment. It's almost impossible to say without seeing the bike and doing a few tests. Sorry I can't be of much help.

[@575ban]

Hello Jim. The side stand needs to be up to do the 15 minutes reset. It won't work with the side stand down.

[@SuperbikeSurgeryTV]

Another Internet myth 🤣 All that happens when you reset the ECU is you wipe the long-term and short-term term fuel trim. The 15-minute idle is just to get it into closed loop for the first time and trim the fuelling. Also, it gets some baseline settings for a good idle. Having the stand up or down makes absolutely no difference.

[@575ban]

@@SuperbikeSurgeryTV fair play mate. Like you say, my knowledge is Internet gained on this stuff, but I will say, on my 2018 1290 Super Adventure, I notice much smoothing on off throttle response after an idle reset. It behaves soo much better ☺️

[@Kravch96]

What if you measure the voltage of the TPS directly using a voltmeter? Wouldnt that achieve the same goal of calibrating the position of the TPS? This would eliminate the need for a very expensive tool

[@SuperbikeSurgeryTV]

I agree with you, but that would be far too simple! As far as I can tell, the value is written into ecu memory during the calibration process. So just adjusting the TPS using voltage in the normal way wouldn't work.

[@markbranton1240]

Awesome video as always, but here's a question, why would anybody design something that sensitive to adjustments? And secondly, why would someone buy that kind of bike if they knew about this situation? Just curious, not bashing the tech.

[@SuperbikeSurgeryTV]

Two good questions I don't have answers for!

[@ekspatriat]

I bought the bike without knowing this issue. It plagues me. There is an other way to hopefully fix this without all the expensive kit. It involves adjusting the sensors using a multimeter and i think millivolts. Also I have Tuneecu and reportedly custom maps help. Otherwise what is the cost of that interface and the reader?

[@hannesdobbelaere]

@@ekspatriat tuneECU should do just fine. just look to add some parameters in the app. i have at least one of the TPS voltages shown somewhere. i too still need to find out all about that app.

[@riccicrozzie8204]

There is a better way to reduce the freeplay between the gears.

[@pauloj.c6921]

hello, can someone, please tell me the reference of the gear? or can someone tell me where to buy a metal gear, as they say that more recent models have this metal gear apparently KTM doesn't sell any of the gears separately. when there is a problem, they simply replace everything. this is completely unacceptable. best regards

[@jimmcinnes8922]

I’ve also enquired at KTM dealer, there are no internal parts for throttle body. Just a complete throttle body on the parts list…? It would help if there was a link to source these parts.

[@ralfgottfridhansson3127]

Why I'd never buy a MC🏍 whit throttle body🙄 (carbs are sow easy to service) 😅

[@Ian-bq7gp]

Why I'd never buy a KTM

[@ktm690limited]

Hi 🙂 It is not the TPS sensor that needs to be unplugged during the recalibration, but the TPS stepper motor! You misinterpreted the instructions. Best regards from Austria, Martin

[@SuperbikeSurgeryTV]

Interesting 👍 I'll pay more attention next time I do one! The instructions in the TEXA documentation do say TPS, but unplugging the stepper would make much more sense, given you are physically pushing against it for part of the adjustment. Thanks for the information. 👍

[@ktm690limited]

@@SuperbikeSurgeryTV You got that exactly right. If you unplug the stepper motor during calibration he will no longer work against it if you close the throttle valve with your fingers. And that is the reason why the stepper motor should be staked during the process. Greetings, Martin

[@Tiger800xr]

Plastic Gears on a motorcycle? Is this the Root causes of so many mechanical problems in ktms? Cheaper internals Made in China. Do all ktm engines use plastic gears in their Throttle body's? WAS this made in China? DO the Cfmoto ktm engines also have plastic gears in their Throttle Bodies??