Jason’s KTM 690 overland bike

This is a much-modified and well-used 2014 690 which had been converted to a rally bike before Jason bought it. It’s the twin-plug single with ride-by-wire throttle control, but without the TFT dash and dual balancers which came in for 2016.

Jason’s plan is to ride it round South America in 2027, and possibly North America too. But first it has to be dependable. I’ll let Jason explain:

“Unfortunately the main wiring loom was eaten through in multiple places and was starting to short out. I replaced it, and made the necessary modifications to work with the mods the bike had. Turned the key and all looked fine – no engine faults or anything. Looked at the rear of the bike and the brake light was blinking. So I hit the brake lever and of course the indicators came on. Got to love it.

“The bike sat for a while and I eventually decided to get it sorted. This time around, when I turned the key it was dead (and the battery was fine).”

Jason brought the bike along for a comprehensive rework: fix the electrics, check over all the accessory connections, and add the ability to run a tyre pump and heated jacket, to go with the heated grips. He also wanted to know whether the alternator could power everything at once. As he was planning to ride over the Andes, this seemed like a really good thing to know.

My apprentice Adam Cameron stripped the bike and conducted a forensic examination and renovation of the entire electrical system. He found a great deal of sadness, as the pics show, so the first job was to chase all that away.

Next job was sourcing and fitting new indicators, a tail light, a volt meter, and some heated grips. We also needed to incorporate the heated jacket and tyre pump safely.

Eventually, after two weeks of extremely complex work, it was done. We also learned that when you disconnect the ECU and ride-by-wire from the battery on these bikes, you have to reintroduce them to each other in a staged way or the bike won’t work.

Jason was amazed at Adam’s four-page PDF report with pics explaining what he’d done, and suggesting jobs still to finish before the big trip. “My honest to goodness response was ‘Wow’,” Jason said afterwards. “I’m really pleased with what you’ve done and will follow up on the other items you mentioned.”

A very satisfying job. And unfortunately the last full-scale one Adam will do before he moves up north to be nearer friends and family, and to start a proper career.