KTM 640 - engine randomly dies - Page 2

Queen of Spades · 01-20-2013, 02:24 PM

I'll snap a pic and upload in a bit.

Queen of Spades · 01-21-2013, 08:01 PM

Laromonster · 01-22-2013, 03:48 AM

You lost yer battery..

Queen of Spades · 01-22-2013, 04:45 AM

Quote:

Originally Posted by Laromonster

You lost yer battery..

http://www.youtube.com/watch?v=3HUGeA2lur4

Queen of Spades · 01-22-2013, 04:53 AM

Returning to the topic at hand, does anyone have a picture of this section of wiring on their 640 LC4? Mine is a 99 model (enduro).

I'm unsure if both of the ends of the yellow/red wire are to be joined and inserted into the white plastic coupling (see the empty brass fitting).

tallbob · 01-22-2013, 02:42 PM

Mine's a 99 640E too. Picture isn't too clear but there are 2 yellow/red wires on one pin and 2 brown wires on the other pin of that connector.

Queen of Spades · 01-22-2013, 03:03 PM

Quote:

Originally Posted by tallbob

Mine's a 99 640E too. Picture isn't too clear but there are 2 yellow/red wires on one pin and 2 brown wires on the other pin of that connector.

That works - suspected they fell out of the connector. Not sure of the best way to get them back in it -- will soldering work here? It seems like it would need to be cleaned off prior to that, though. Any ideas?

bmwktmbill · 01-22-2013, 04:48 PM

Problems like this are difficult.

You will have to release the connector from the plug with a pick, resolder and then reinsert.

Sometimes that works. If it doesn't you will need new stuff to somehow recreate the connection.
bill

Queen of Spades · 01-22-2013, 04:58 PM

Quote:

Originally Posted by bmwktmbill

Problems like this are difficult.

You will have to release the connector from the plug with a pick, resolder and then reinsert.

Sometimes that works. If it doesn't you will need new stuff to somehow recreate the connection.
bill

Have you seen any youtubes or pictoral guides on how this is done (releasing fitting from connector with a pick)?

bmwktmbill · 01-23-2013, 05:52 PM

No, you will have to use skill and imagination.
the rest if the forum can jump in anytime.

Usually there is a spring loaded clip thar retracts as it is pushed ahead, then snaps into place.

Check this out.

http://www.mcmelectronics.com/browse...ors/0000000675

bill

clintnz · 01-23-2013, 07:15 PM

Quote:

Originally Posted by Queen of Spades

Have you seen any youtubes or pictoral guides on how this is done (releasing fitting from connector with a pick)?

Go to an electronics, auto sparky or auto parts store & get some new spade terminals to go in the plugs, should only be a few cents. The connectors come in all different shapes & sizes but the actual terminals inside are fairly standard. Once you have the new bare terminals you'll see how they are retained.

Cheers
Clint

Queen of Spades · 01-24-2013, 11:39 AM

Quote:

Originally Posted by clintnz

Go to an electronics, auto sparky or auto parts store & get some new spade terminals to go in the plugs, should only be a few cents. The connectors come in all different shapes & sizes but the actual terminals inside are fairly standard. Once you have the new bare terminals you'll see how they are retained.

Cheers
Clint

We don't have an Auto Sparky (though I wish we did - love the name!), but I will drop in at a Radio Shack and see if they still sell anything remotely close to what we are talking about.. Used to be a good place to get electronic parts, but now they are geared up as a phone dealer with a few odd audio/power cables.

ChrisC · 01-24-2013, 01:27 PM

Google "McMaster Carr" - they have all sorts of 12V connectors, including waterproof, so you could rewire and replace the faulty connector...

wrk2surf · 01-24-2013, 04:36 PM

radio shack does have molex connectors similar that come with the new pins and they sell the tool .. works in a pinch !

Queen of Spades · 01-26-2013, 01:04 PM

Good news/bad news.

Good: made a tool to get the molex connector removed. It worked.

I crimped the wires back to the clip and soldered the connection too. It is snug as a bug.

More good news: it started up no problem. Warmed the engine up, then let it idle while I went over to talk with a neighbor.

About 5 minutes later I heard the bike stall out of nowhere. The headlight stays on, it just won't start. I've jiggled the connections, taken them apart and put them together. Fuses ok.

Exact same f'ing problem as before.

I want to pull my hair out. What else would randomly cause it to die? Nothing else in the battery area is loose or worn/exposed.

01-20-2013, 02:24 PM	#16
Queen of Spades ^OP tall drink of water Joined: Mar 2009 Location: Decatur, GA Oddometer: 344	I'll snap a pic and upload in a bit. __________________ '99 KTM 640 LC4 Enduro http://www.youtube.com/watch?v=Vl7XlZs2CRc (May 2013 trail riding) '02 Kawasaki KX250 L4 http://www.youtube.com/watch?v=Sjgw-yZJdfs (Jan 2013 gopro )

01-21-2013, 08:01 PM	#17
Queen of Spades ^OP tall drink of water Joined: Mar 2009 Location: Decatur, GA Oddometer: 344	__________________ '99 KTM 640 LC4 Enduro http://www.youtube.com/watch?v=Vl7XlZs2CRc (May 2013 trail riding) '02 Kawasaki KX250 L4 http://www.youtube.com/watch?v=Sjgw-yZJdfs (Jan 2013 gopro )

01-22-2013, 03:48 AM	#18
Laromonster Vesperado ! Joined: Jun 2004 Location: Stavanger Norway Oddometer: 1,255	You lost yer battery.. __________________ Laromo '91 Vespa PX 200E "Lusso" '05 KTM 640 ADV "Fatman" '99 HD FLHRCI "Leviathan"

01-22-2013, 04:53 AM	#20
Queen of Spades ^OP tall drink of water Joined: Mar 2009 Location: Decatur, GA Oddometer: 344	Returning to the topic at hand, does anyone have a picture of this section of wiring on their 640 LC4? Mine is a 99 model (enduro). I'm unsure if both of the ends of the yellow/red wire are to be joined and inserted into the white plastic coupling (see the empty brass fitting). __________________ '99 KTM 640 LC4 Enduro http://www.youtube.com/watch?v=Vl7XlZs2CRc (May 2013 trail riding) '02 Kawasaki KX250 L4 http://www.youtube.com/watch?v=Sjgw-yZJdfs (Jan 2013 gopro )

01-22-2013, 02:42 PM	#21
tallbob Studly Adventurer Joined: May 2005 Location: Butt Mt. VA Oddometer: 509	Mine's a 99 640E too. Picture isn't too clear but there are 2 yellow/red wires on one pin and 2 brown wires on the other pin of that connector. __________________ Twin Valley Riders

01-22-2013, 04:48 PM	#23
bmwktmbill Traveler Joined: Jul 2005 Location: Traveler Oddometer: 4,014	Problems like this are difficult. You will have to release the connector from the plug with a pick, resolder and then reinsert. Sometimes that works. If it doesn't you will need new stuff to somehow recreate the connection. bill __________________ '02 KTM 640 Adventure-lowered "On the road there are no special cases." Cormack McCarthy-The Crossing The faster it goes the faster it breaks. And high performance=high maintenance. Bill Shockley

01-23-2013, 05:52 PM	#25
bmwktmbill Traveler Joined: Jul 2005 Location: Traveler Oddometer: 4,014	No, you will have to use skill and imagination. the rest if the forum can jump in anytime. Usually there is a spring loaded clip thar retracts as it is pushed ahead, then snaps into place. Check this out. http://www.mcmelectronics.com/browse...ors/0000000675 bill __________________ '02 KTM 640 Adventure-lowered "On the road there are no special cases." Cormack McCarthy-The Crossing The faster it goes the faster it breaks. And high performance=high maintenance. Bill Shockley

01-24-2013, 01:27 PM	#28
ChrisC Molon Labe Joined: Feb 2003 Location: Prescott, Arizona USA Earth Oddometer: 6,286	Google "McMaster Carr" - they have all sorts of 12V connectors, including waterproof, so you could rewire and replace the faulty connector... __________________ Chris '03 KTM Adventure 640 '43 BSA M20WD

01-24-2013, 04:36 PM	#29
wrk2surf BITD/Rallye Joined: Dec 2007 Location: THE exact center of California/Bass lake/Yosemite Oddometer: 5,312	radio shack does have molex connectors similar that come with the new pins and they sell the tool .. works in a pinch ! __________________ Thanks for the 2013 support: DUNLOP, BELL HELMETS, Kriega USA, Carbon-pro.com, Ride 100% Goggles, Renazco Racing, Sidi/Motonation, Acerbis USA,KLeN, FMF, Mx1west,,Masters paint and body, Magura , motolab ,and Freedom Cycle

01-26-2013, 01:04 PM	#30
Queen of Spades ^OP tall drink of water Joined: Mar 2009 Location: Decatur, GA Oddometer: 344	Good news/bad news. Good: made a tool to get the molex connector removed. It worked. I crimped the wires back to the clip and soldered the connection too. It is snug as a bug. More good news: it started up no problem. Warmed the engine up, then let it idle while I went over to talk with a neighbor. About 5 minutes later I heard the bike stall out of nowhere. The headlight stays on, it just won't start. I've jiggled the connections, taken them apart and put them together. Fuses ok. Exact same f'ing problem as before. I want to pull my hair out. What else would randomly cause it to die? Nothing else in the battery area is loose or worn/exposed. __________________ '99 KTM 640 LC4 Enduro http://www.youtube.com/watch?v=Vl7XlZs2CRc (May 2013 trail riding) '02 Kawasaki KX250 L4 http://www.youtube.com/watch?v=Sjgw-yZJdfs (Jan 2013 gopro )

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