03 KTM 640 Adv -- Electrical Problem

Discussion in 'Thumpers' started by alpiv, Sep 28, 2006.

  1. alpiv

    alpiv Sr. nOOb

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    I was our riding and had to turn around (missed a turn), turn the bars to the left to make a left turn, felt resistence and as I cleared the resistence, the bike shut off.
    Turn the bars streight, it would start and run fine. Yet when I turn the bars far left, about the time the keyswitch would pass the frame it would shut off --Like I was grounding the system out.

    Anyone else have this problem ?
    #1
  2. gaspipe

    gaspipe Wandering Soul Super Moderator

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    Wonder if the ignition switch leads pulled out of the soldered contacts.

    It happened to me on the CD Ride. Check the pigtail coming from the bottom of the switch. It's about a foot long, and goes into a molex connector on the right side fairing brace.

    LVR resoldered them in the field.

    Check it out and let us know.

    :ear
    #2
  3. fire_strom

    fire_strom Long timer

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    If it turns out not to be what Gaspipe mentioned you might check the choke cable. mine got hung up on somthing so that it'd die abruptly when the bars turned full lock. do your lights shut off or just the motor?
    scott
    #3
  4. billy bee

    billy bee AAdventurer

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    I had the same experience with the choke cable...

    bb
    #4
  5. jfn68

    jfn68 Banned

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    my 99 adv did that,it broke a wire about 100mm forward of the ignition switch,it was either white or yellow,on the rhs.
    #5
  6. alpiv

    alpiv Sr. nOOb

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    No, shuts everything off and I have to turn the key off then back on to get it to start..
    I broke the front end down this evening and could not find anything loose or frayed something.

    Bike starts fine and still runs with bars turned..

    I checked for obstructions or pulled wires with nothing showing..

    Gaspipe: Which wires came loose on yours?
    #6
  7. gaspipe

    gaspipe Wandering Soul Super Moderator

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    You have to disassemble the switch. The black plastic bottom part of the switch has a hole in the middle where the wiring pigtail goes into the switch. Inside there is where the wires pulled off the soldered terminals.

    If your IMO goes all wonky and dies or is blank, and the motor dies like you turned the ignition off, I am betting that's what it is.

    A pic from the ride report, page 20:

    [​IMG]

    HTH,

    Bruce
    #7
  8. OldnoGPS

    OldnoGPS Just a sightseer

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    You should whip the guy who sold you that thing! (Kidding, it was me.)
    FYI - I never had it do that to me. Or anything else, bike was totally reliable.
    My old DR650 would cut off turning left like that from the choke as was mentioned. With the tank off it didn't do it, just enough extra stretch with it on that it did. Rerouting fixed it but it was hard to find, I thought sure it was electrical.
    Gaspipe surely knows more than me about the thing. I do know that what I saw of the harness/connectors on that bike were all as new and clean.
    Sorry it's being cantankerous.
    Is the clutch interlock still connected, maybe being pulled on? (I never removed the interlocks, don't know why - first thing I did on my DRZ and XR).
    Ted
    #8
  9. FBOMB

    FBOMB Re-noobed

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    +2 on the choke cable issue. If I would turn the bars all the way
    to the right, instant shut down. I removed the tank and found
    2 broken zip ties that where used to hold the choke cable
    to the frame. I rerouted the choke cable and used heavy duty
    zip ties and have not had the problem since.

    Hope this helps.
    #9
  10. alpiv

    alpiv Sr. nOOb

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    It was the PO's fault!

    Normal wear and tear does this..
    The pig tail is a loose and as one turns the steering head it moves withing the lower housing of the switch.
    [​IMG]

    I had three frayed wires..
    I took it apart and re-soldered each connection.
    I would check this before any long distance run....

    Many thanks "GP"
    #10
  11. gunnerbuck

    gunnerbuck Island Hopper

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    I had the same thing go on my 03, upon reassembly after soldering I put a lump of silicone aound the wire before I slid the base cup back in place. By doing this I hoped to stop the twisting action on the terminals, it's been about 20,000 KM since my fix and I have had no further problems with the keyswitch assembly.
    #11
  12. PackMule

    PackMule love what you do Super Moderator

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    Nominating for the index...
    #12
  13. alpiv

    alpiv Sr. nOOb

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    Thought about doing that too. Guess I'll be pulling it apart again..
    Better safe then sorry.

    Many thanks
    #13
  14. OldnoGPS

    OldnoGPS Just a sightseer

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    Al,
    Glad you/Gaspipe found the problem. I knew I should have just been riding with the front wheel in the air and steering with the throttle and body english instead of turning them bars!!!
    I'll pass this on to the local 640'ers.
    Ted
    #14
  15. svenb

    svenb Been here awhile

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    See the attached image. I had have some problems during this season on my 2003 640 Adv.

    Quite often It will not start, similar to no juice in the battery. Displays shut´s off, starter klicks. If I use decomp I might get it started. Otherwise I have to kickstart. Then it works fine for a day or two. Strange

    On my latest trip it was more serious. When I was as far from home I could be it wont start or let me kickstart it. I had to use cables from a friend.

    Next problem was when I tried to use Hi beam, It just shut off the whole bike. No power at all, cables again.

    If you look carefully, you can see that Blue and Red White are not soldered and they has been loose for a while.
    According to wiring diagram, those cables are not in use, but what if they touches another cable?

    Any ideas?

    Attached Files:

    #15
  16. alpiv

    alpiv Sr. nOOb

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    I'm wondering if this (again) is not the cause of my current problems...
    Everything works on the bike, except no spark.
    Light, turn signals, break lights work as well as the engine turns over, yet no spark.

    Coil, pulse coil, stator have all been replaced.

    Still no spark..

    Who has a wiring diagram I can look at?
    #16
  17. ChrisC

    ChrisC Amal sex?

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    Check your PM...

    [​IMG]
    #17
  18. explodingmouse

    explodingmouse Been here awhile

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    I have the same problem , how do you get the base cup off to get to the pigtail connections?
    #18
  19. alpiv

    alpiv Sr. nOOb

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    Pocket knife....
    #19
  20. alpiv

    alpiv Sr. nOOb

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    Good News & Bad New...

    Good news is the dealer found the problem(s)...

    One of the original owners cut into the wiring harness near the subframe attachment, boogered it all up...

    So it can be fixed (plus new stator and coils)...


    BAD NEW -- wiring harness is back ordered three weeks...:eek1
    and the bikes been down all summer...
    #20