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Old 09-02-2014, 12:09 PM   #1
Yooper_Bob OP
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KTM 640 Adventure - Blinker gone bonkers!

So....I've got a 2007 KTM 640 Adventure with just shy of 15K miles on the clock. Everything has been working great, up until my last ride.

Suddenly my left blinker started going bonkers.

When I turn on my left blinker, the dash lights, the headlights, and taillight all start flashing, while the left side front/rear blinkers just barely flash.

All of the other electronics work just fine.

Definitely electrical, but.....see here: http://www.advrider.com/forums/showthread.php?t=969529

I have pulled the dash off, pulled apart the main wiring harness connectors, and did a test with a jumper wire between the flasher and the left/right turn signals. The right blinker works fine, but the left one causes the wild flashing of "everything". This clears any problem with the switch itself on the handle bars, or the wiring from the switch to the main harness connector.

I also checked both bulbs, and they are just fine. Cleaned the connectors on each, just to be safe.

Blinker fluid levels are adequate, and fresh fluid has been installed.

So....anyone got any good ideas of what else to look for and how/where to continue? (short of stripping down the entire bike)
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Old 09-02-2014, 01:27 PM   #2
MrPulldown
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This sounds interesting.

First off, does your headlight low beam work. Is it burnt out?

Next do you have LED turn signals. Did you use resistors to solve the turn signal flasher issue?

Have you been doing any wiring on the bike recently?

I believe that your KTM uses a 2 prong flasher relay. If you jump the two connectors and delete the relay you will have eliminated the flashing of the turn signals, they should be just solid when you turn them on. Is this true? This can help with your trouble shooting.
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Old 09-02-2014, 01:30 PM   #3
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[QUOTE=Yooper_Bob;24985217

I also checked both bulbs, and they are just fine. Cleaned the connectors on each, just to be safe.

[/QUOTE]


Did you check all four bulbs?
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Old 09-02-2014, 01:45 PM   #4
Yooper_Bob OP
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Wiring is 100% stock.

Blinkers are NOT LED.

Hi/low beams are working fine.

All 4 blinker bulbs work.

Right blinkers function just fine.

Turn on left blinkers, and dash/headlight/taillight all start flashing...and left blinkers do also...but very dim.
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Old 09-02-2014, 02:35 PM   #5
mancunian
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I recently had a very similar issue on my 2002 640 adv mine did the same and blew a fuse also but not allways, the fault on mine was wear in the wiring harness near the back light where the flasher wires and tail light wires are all a little snug shall we say, worth a look under the tail light hope this helps
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Old 09-02-2014, 02:47 PM   #6
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Is this your wiring diagram or close?


Nothing seems very obvious other than a short of some sort. The power from the L turn signal is back feeding the system (headlight and other stuff) through the ground.

I suspect the "V" wire is somehow touching the "Br"
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Old 09-02-2014, 03:00 PM   #7
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That is pretty much a match to the wiring diagram in the owners manual I have.

Yeah....figured something is touching that shouldn't be.

One strange thing to note...if the bike has been sitting for an hour or so, when you first turn on the key, and hit the left blinker, it works temporarily....for about 3-5 seconds...then it starts the whole flashing deal.

Almost like something heats up, and then starts shorting.
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Old 09-02-2014, 04:40 PM   #8
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As others have noted, I would suggest checking all your wiring under the headlight mask. You will probably have an earth fault somewhere.

Especially check the wiring that runs immediately next to the steel cross brace under the mask. I have seen the wires almost cut through the steel here with no damage to the wires! It's amazing what vibrations will do.

Its probably a good idea to unwrap the insulation from ALL the wiring loom under there, check each wire individually and re-wrap with some heavy duty spiral wrap. Make sure all wires are tightly secured to the frame.
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Old 09-04-2014, 06:35 AM   #9
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Finally solved it!

Dug through all of the wiring under the dash, and nothing.

I then removed the right side panel that covers the ECU and other assorted electrical gadgets....and there it was. The purple wire that runs to the left rear blinker had rubbed through a pink wire, and the two were shorting out. Not sure where the pink wire runs to...but at this point, what do I care?.

Anyway...separated the wires, and SUCCESS! Blinkers are now working correctly again!

It is amazing that this shorting did not blow any fuses.

Sent the wife to the store today to pick up some liquid electrical tape. I will patch things up tonight after work, and hopefully be able to reassemble the bike back to its original state.

Thanks for the various hints/advice.
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Old 09-04-2014, 11:10 AM   #10
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Old 09-04-2014, 11:46 AM   #11
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right on.
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Old 09-04-2014, 06:58 PM   #12
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Got things all put together tonight....although, had to do half the work in the dark, due to local power outages.

Everything works as it should....all that's left now is to take it for a ride this weekend!
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