'03 KTM Adventure clutch switch

Discussion in 'Thumpers' started by creeper, Mar 28, 2004.

  1. creeper

    creeper Still alive...

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    The information below pertains to the US ’03 KTM 640 Adventure. It may also be of use to any street legal KTM LC4 model including the enduro, Duke and Motard... and possibly the 950 Adventure.

    For almost a year now I’ve been pondering as to why my bike must be in neutral to start. Obviously, I haven’t pondered that much or I would have investigated the issue sooner.
    Anyway, after reading the translated (?) starting description and staring at the wiring diagram, I came to the conclusion that there was a problem with either my clutch switch or the diode it is wired to and I should in fact be able to start the bike in any gear with the clutch pulled in.

    I removed the fairing, hooked a multimeter to the two-pin plug connection on the clutch switch and saw no change in resistance when I pulled in the lever… Ah Ha! Bad switch!
    I removed the offending switch and retested it (yes, I’m like that) and found less than 1 ohm continuity when I pushed the plunger in with my finger… Ah Ha! Good switch!

    Apparently, after examining the parts, it appears that the relationship of switch plunger, the “bump” on the clutch lever intended to depress the plunger, and there proximity to each other was insufficient to engage the switch.
    I could see no way to make the lever “bump” higher, or to extend the plunger, so I looked at ways to increase the depth in which the switch screwed into the clutch master cylinder casting.
    If I had a mill, it would have been a simple thing to “face off” a bit of the boss (oddly enough, about .060”) that extends out away from the master cylinder casting, allowing the switch (and plunger) to go deeper into the casting, and the plunger to be in closer proximity to the clutch lever.
    Instead, I used a hand held lathe, designed to turn down the necks of benchrest rifle cartridge cases, to remove approximately .060” from the shoulder of the switch.
    This was sufficient for the lever to fully depress the switch plunger, providing continuity for the diode and finally… in gear starts for me. Ta Da!

    I may be the only one on the planet that had this problem… but I doubt it.

    Creeper

    First view is relationship of parts

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  2. creeper

    creeper Still alive...

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    A view of the switch and material removed (shiny area)

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  3. creeper

    creeper Still alive...

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    A view of the master cylinder boss.

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  4. dagwood

    dagwood Banned

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    Mine took a dump and would periodicly "kill" the motor while in motion. Nada, not gonna happen again. thew that pos away. Beware if anyone else rides my bike, it will start in gear with the clutch out. :evil
    #4
  5. Frank Warner

    Frank Warner Traveller

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    That can be a handy feature .. pushing the bike out of a river (motor won't start) and you cannot push it over a log/bump simply use the starter to get you over that hard bit.. not for continuous use though.

    And Yes - the cluctch switches and side stand switchs on all of my bikes have been removed.. problems waitin to happen if you ask me.
    #5
  6. rapiti

    rapiti IOR Veteran

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    POS hydraulic clutch!
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  7. creeper

    creeper Still alive...

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    Yea, I considered bagging the whole starter "safety" package. I want to see if it all works for awhile, correctly, before I do.

    Creeper
    #7
  8. Gary

    Gary Another Adventure Rider

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    My sidestand switch failed a couple of weeks ago on my LC4E, bike only has 3000 miles, but the wires take a beating under there where the switch is. Removed the wire and re-inserted the electrics source pins (under the seat) together and problem solved for that switch. Looks like I need to get a different bolt for the sidestand inorder to actually remove the (now disconnected) switch itself.

    Anyone care to offer a quick rundown on removing/disabling the clutch switch on an LC4 w/cable clutch?

    Thanks,
    Gary
    #8
  9. dagwood

    dagwood Banned

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    cut the wires and solder them together, put a piece of shrink toobing over the exposed end and stuff it back under top tripple clamp.
    #9
  10. Gary

    Gary Another Adventure Rider

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    Thanks Dagwood. That seems simple enough!

    Gary
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  11. kurtw

    kurtw Child of the Wind

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    When I installed my KTM sidestand, I first removed the switch. I believe that the small bolt that holds the switch serves only that purpose, so with the switch gone, I didnt bother replacing the bolt.
    #11
  12. gozell

    gozell Adventurer

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    Hi Creeper,

    Your post made my realise that im having the same problem with my 03 Adv, unable to start with clutch pulled in...

    Had a quick fiddle and pulled the clutch switch from its socket without too much trouble... Perhaps i need to screw it in again or do some like you described above..

    Will have a closer look tomorrow.

    Grtz
    #12
  13. creeper

    creeper Still alive...

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    Test the switch off the bike... it probably works. If you know someone with a small lathe, that would be the easiest way to turn down the shoulder of the switch.

    Thats two. If it goes five, I'm gona' contact KTM.

    Creeper
    #13
  14. BlownCJ

    BlownCJ dangerous rider ?

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    im there to creep my new bike only starts in neutral with clutch out :eek1

    if ya stall it your fucked :huh

    got my 03 adv on friday in new hampshire put on 17 tooth ctrshft abd 42 rear sprocket ......... made to my home in north ga sunday morning at 6 am
    grand happy ass total 1270 miles .... :deal

    BARRY new 03 640 adv
    #14
  15. creeper

    creeper Still alive...

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    Thats three. That is three isn't it? :lol3
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  16. daotoys1

    daotoys1 Long timer

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    I have shit canned the starter safety crap off each and every bike I have ever owned.....

    I see this stuff as excess weight and unneeded extra electrical stuff that gets in the way and is only a problem(s) waiting to happen...

    I have never had any complications from eliminating this junk on any bike....all you have to do is look before you leap/rip/tear/cut.....just make sure you know how the stuff/swithes and the like are wired...and how they work ( usually open on or open closed variations).....then systematically remove the items down to the source(harness)...
    :freaky :freaky :freaky
    #16
  17. trialsguy315

    trialsguy315 Accidental Tourist

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    I'm with Dao - junk the crap. the kickstand interrupt can screw you at the worst time, the clutch lever switch can go bonkers from catching brush in it, not even falling over. Just the govt protecting us from ourselves.

    the ability to use the starter as a motion device I found very helpful when I had a KLR.
    #17
  18. d0gWateR

    d0gWateR Goat Stuntaz DSMC

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    Creep, yer amazing. "..just take my trusty Binford 5000 hand lathe..." I'm in awe. :bow Hehe j/k.

    I pick up my brand new '03 640 Adv next Thurs, you can bet I'm gonna try that out at the dealer. Thanks for the heads up.
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  19. creeper

    creeper Still alive...

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    So Dog, where'd ya' get a new '03 Adventure? Congratufreakinlations! Hope you didn't get hosed on the price, I've heard of US dealers getting all greedy... if they still had one in stock.

    Yep, if it starts in gear with the clutch in, your good to go.

    Creep

    Oh yea', thats a Sinclair 3000 hand lathe :lol3
    #19
  20. dagwood

    dagwood Banned

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    WTF?
    #20