KTM 690 developed deep exhaust sound, lost all power, then died. Only 22k km
My 2017 KTM 690 Duke has officially had what I call “The Day of Doom” and I genuinely don’t know what happened.
For almost a year, the bike had a small issue where it would occasionally stall while slowing down with the clutch pulled in. Usually intersections, roundabouts, low RPM situations, etc. It happened maybe once a week and always restarted instantly, so I ignored it.
During winter storage I accidentally connected the battery charger backwards and blew the main fuse, but after replacing that the bike seemed completely normal again.
This season the stalling slowly became more frequent. Then eventually the starter started struggling more and more too. Sometimes it needed several seconds of cranking before starting.
Then came the Day of Doom.
Earlier that day the bike barely started at all. Later that evening it completely refused to start normally and needed a jump starter.
After getting it running, I went for a ride and while leaving an intersection: boom — the bike dies while moving.
Previously it had ONLY stalled while slowing down and always restarted instantly. This time it would NOT restart while riding. (This is when the video was recorded)
After getting it running again, I continued riding home. Since the bike usually stalled while dropping RPM, I kept revving/blipping the throttle through a large highway exit turn to keep RPMs up.
The SECOND I exited the turn, the exhaust suddenly sounded WAY deeper than normal. Not powerful deep — weak and grumbly deep.
At the exact same time: the bike suddenly had almost no power at all.
It felt like trying to accelerate in way too high of a gear. I downshifted all the way to 1st and it still barely accelerated.
I kept riding for maybe another 30 seconds thinking maybe it would clear up, but eventually it basically lost all power.
Pulled over and shut it off.
Then somehow, after jump-starting it AGAIN, it actually started.
But now:
- the exhaust sounded different again
- and there was a random metallic hammering/rattling noise coming from underneath the bike
Not rhythmic engine knock. Not really RPM dependent. Just random metallic hammering/rattling from underneath.
I revved it a little while idling just to hear it, and honestly the engine itself didn’t sound blown.
Then I shut it off.
That was the last time it ever ran.
A few days later it wouldn’t start even with a jump starter, and now the workshop can’t get it started either.