KTM 690 Fuel Tank Upgrades

When venturing off the beaten track or embarking on long-distance tours, the standard fuel tank capacity on many motorcycles can often feel restrictive. For owners of the popular KTM 690 series, extending the riding range is a common desire, allowing for more exploration and fewer fuel stops. While the 690 Enduro and SMC models come with a respectable stock fuel tank, the aftermarket offers a wealth of options for those seeking to significantly increase their mileage. This article delves into the world of aftermarket fuel tanks, focusing on what riders need to know to make an informed decision, particularly in relation to models like the KTM SXC 625 and similar LC4 platforms, which share many design characteristics with the 690.

Understanding Your KTM's Fuel Needs

The KTM 690 platform, encompassing models like the Enduro R and SMC R, is renowned for its versatility, capable of tackling both off-road trails and spirited road riding. The stock fuel tank capacity typically hovers around 12-13 litres, offering a decent range for general use. However, for extended adventures, the need for a larger capacity becomes apparent. This is where aftermarket manufacturers step in, providing significantly larger tanks that can dramatically improve your motorcycle's touring potential. It’s crucial to understand that while this article draws specific examples from the SXC 625, the principles and considerations are highly relevant to the broader 690 lineage.

The Benefits of an Extended Range Fuel Tank

Installing a larger fuel tank offers several compelling advantages:

• Increased Range: The most obvious benefit is the ability to travel further between refuelling. This is invaluable for remote exploration, long-distance touring, and reducing the anxiety of running out of fuel in unfamiliar territory.
• Fewer Stops: Less frequent stops for fuel mean more time spent riding and enjoying the journey.
• Convenience: For long-distance riders, carrying less fuel in separate containers can be more convenient and safer.
• Improved Weight Distribution (Potentially): Some aftermarket tanks are designed to integrate seamlessly, potentially offering better weight distribution compared to strapping extra fuel cans to the bike.

Key Considerations When Choosing an Aftermarket Fuel Tank

When looking to upgrade your KTM's fuel tank, several factors require careful consideration:

Capacity and Range Extension

Manufacturers offer tanks in various capacities. For instance, the Safari Tanks mentioned for the SXC 625 offer a 17-litre option, which is a substantial increase over a typical 10-13 litre stock tank. This can effectively almost double the motorcycle's range, depending on the fuel efficiency of the specific model and riding conditions. It’s important to balance the desire for maximum range with the practicalities of tank size and weight.

Fitment and Compatibility

This is perhaps the most critical aspect. Not all aftermarket tanks are universally compatible, even within the same brand or model family. As the provided information for the SXC 625 highlights:

• Model Specificity: Tanks are often designed for specific models or series (e.g., SXC 625, LC4 620/640).
• Seat Compatibility: The shape and profile of the motorcycle's seat can affect tank fitment. The SXC640 seat, for example, has a different profile to the SXC 625, potentially requiring modifications.
• Potential Modifications: For older models or those with specific configurations, minor modifications might be necessary. This could include replacing standard bolts with button head bolts to avoid interference with the tank, or adjustments for the seat, fan, or anti-pollution equipment.
• Carburettor Type: Some tanks may not be compatible with certain carburettor types, such as Constant Velocity (CV) carbs. Always verify this.

It is paramount to carefully check the manufacturer's specifications and compatibility notes for your specific KTM 690 model (Enduro R, SMC R, etc.) before purchasing.

Material and Construction

Most aftermarket fuel tanks are constructed from durable plastics like high-density polyethylene (HDPE). This material is chosen for its impact resistance, chemical stability (resistance to fuel), and relatively light weight. The construction quality, including the thickness of the plastic and the integrity of the seams, will determine the tank's longevity and reliability.

Aesthetics and Ergonomics

While functionality is key, aesthetics and how the tank integrates with the bike's overall design are also important. Some tanks are designed to be very slim between the knees, maintaining the original feel of the motorcycle, while others may be wider. The colour options, such as Orange, Black, or Translucent, allow riders to match or complement their bike's existing plastics. It's worth noting that aftermarket colours, like the 'Orange' mentioned for the SXC tanks, may not perfectly match the factory KTM orange.

Included Components

Check what is included with the tank. Typically, a new fuel cap and breather line are provided. However, a fuel tap is often omitted, meaning you may need to reuse your existing one or purchase a compatible one separately. Always confirm this to avoid surprises during installation.

Installation Process

Installing an aftermarket fuel tank can range from a straightforward bolt-on job to a more involved process requiring minor modifications. As indicated by the availability of an installation manual for the SXC 17-litre tank, these are generally designed for DIY installation by mechanically inclined individuals. However, if you are not comfortable with motorcycle mechanics, it is always advisable to have a professional workshop handle the installation to ensure it is fitted correctly and safely.

Example: Safari Tanks for KTM LC4/SXC Platform

The Safari Tanks 17-litre tank for the KTM SXC 625 serves as an excellent example of an extended-range solution. Its design aims to:

• Increase Range: Almost doubling the original capacity.
• Maintain Ergonomics: Designed to be no wider between the knees than the standard tank, with extra fuel capacity housed where the shrouds typically sit. This is particularly beneficial for navigating tighter trails.
• Offer Colour Choices: Available in Orange, Black, or Translucent.

The notes regarding fitment highlight the importance of checking compatibility with specific seats and potential minor modifications for certain models (like the 620s) or components (like air box bolts).

Comparison Table: Stock vs. Aftermarket Extended Range Tank

To illustrate the differences, consider this general comparison:

Frequently Asked Questions (FAQ)

Q1: Will a 17-litre tank fit my KTM 690 Enduro R?

While the 17-litre Safari Tank is specifically mentioned for the SXC 625 and LC4 models, manufacturers often produce tanks for the 690 Enduro R and SMC R. You must consult the specific product details for your 690 model. KTM's parts and aftermarket suppliers will list direct compatibility. Always verify fitment with the manufacturer or a reputable dealer.

Q2: Can I install an aftermarket fuel tank myself?

For many aftermarket tanks, especially those designed with good fitment in mind, DIY installation is possible for individuals with basic mechanical skills and tools. However, if the installation involves complex routing of fuel lines, potential interference with electronics, or modifications to the bike's frame or bodywork, professional installation is highly recommended to ensure safety and proper function.

Q3: Will a larger fuel tank affect my bike's handling?

Yes, a larger fuel tank, when full, will add weight to the motorcycle. This increased weight, especially if placed higher up, can affect the bike's centre of gravity and overall handling characteristics. However, this is generally a manageable trade-off for the extended range, and manufacturers often design their tanks to integrate as smoothly as possible to minimize adverse effects. The weight difference is most noticeable when the tank is full and diminishes as the fuel is consumed.

Q4: Do I need to change my fuel tap or fuel pump?

This depends on the specific aftermarket tank and your motorcycle's original setup. Some aftermarket tanks will utilize the original fuel tap and pump. Others might require a specific fuel tap, which may or may not be included. If your KTM 690 uses an electric fuel pump integrated into the stock tank, you will need to ensure the aftermarket tank is compatible with this system or comes with a suitable replacement. Always check the product description and included components.

Q5: What colours are typically available for KTM fuel tanks?

Common colours for aftermarket KTM fuel tanks include the classic KTM Orange (though shades may vary), Black, and sometimes Translucent or White. Translucent tanks can be useful for visually monitoring the fuel level.

Conclusion

Upgrading your KTM 690's fuel tank is a popular and effective way to enhance its touring and adventure capabilities. By carefully considering capacity, ensuring precise fitment for your specific model, understanding the materials and installation requirements, and checking what components are included, you can significantly extend your riding range and enjoy more miles of exploration. Always refer to manufacturer specifications and, if in doubt, seek professional advice.

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