04 950 Adventure electrical problems

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by themotojourney, Nov 2, 2012.

  1. themotojourney

    themotojourney Adventurer

    Joined:
    Oct 15, 2011
    Oddometer:
    12
    Location:
    Salisbury Plain, UK
    I commute on my KTM 950 Adventure, racking up about 10k miles this year across London in all weathers. I know it's not the most reliable commuter bike but its mine and I love it.

    Dealt with a few common glitches already, like a blown clutch seal and a hair raising ride without stopping to get home!

    This time it's more serious. I have been having more and more problems with electrical power failures. I used to have fairly rare power cut outs. Sudden total loss of power and then it would click back on.

    Last week the battery slowly died over a days riding so I got a new regulator and fitted it and got the battery charging again this week. 'No probs' I thought.

    Then yesterday the power cut out completely. Total failure on the Westway going into London. I was lucky to get to the side of the road with no lights or power. The two day old main fuse in the starter relay was already showing signs of heat damage and the connection point for it looked pretty dirty. So a clean and she started again and we were home.

    Today the power cut out intermittently on the way into work, especially when I put the heated grips and the headlights on. But it always came back.

    On the way home the power cut out and checking all the connections, cleaning the starter relay connection and swopping the fuses didn't do anything. So it's in nearby garage waiting for me to work out what to do next!

    I'm thinking buy and fit a new starter relay but am not sure. Could it be a catastrophic battery failure because of the earlier regulator problem?
    #1
  2. Dustodust

    Dustodust Long timer

    Joined:
    Oct 9, 2009
    Oddometer:
    1,422
    Location:
    Hillsboro Oregon
    it wont help to start throwing parts at it
    you will need to troubleshoot

    start at the battery, trickle charge and test the battery for voltage, it should read 12.8volts or more at rest,

    next check the battery leads : a most common problem on the 9xx adventures
    gain access to the battery, turn on the key and try to wiggle the battery and look at the guages on the dash , if all the digital reads stay stable, you are OK

    if the battery leads are good check all the fuses , sometimes they look OK but the break is not visible
    you can check for continuity with a multimeter

    if the fuses are good check wire connections for continuity
    a good indicator is the speedo readout , or a test light, wiggle and tug wires while someone watches the dash panel

    then if not loose connections, check wire continuity , the wires running up the frame from the battery especially

    start tracing the power from the battery on with a test light
    if its intermittent clamp the test light on and wiggle wires and connections

    also check the key switch for faiure , hook up a test light to the wires in and out as you wiggle the switch

    most electrical problems are caused by :(in order of probablity)
    failed connections
    failed batteries
    failed switches
    failed wires
    failed charging system
    #2
  3. AdvGa

    AdvGa Long timer

    Joined:
    Nov 25, 2009
    Oddometer:
    1,320
    Location:
    Atlanta Metro
  4. themotojourney

    themotojourney Adventurer

    Joined:
    Oct 15, 2011
    Oddometer:
    12
    Location:
    Salisbury Plain, UK
    Thanks very much indeed! I will head up to the garage tomorrow (buying a multimeter en route) and use their yard to run the tests properly. Fingers crossed.
    #4
  5. 6732cash

    6732cash Been here awhile

    Joined:
    Jul 15, 2007
    Oddometer:
    179
    Location:
    ..London
    You said the new main fuse was showng signs of heat damage ...this could mean the conectors it sits in are shot the only way is a new solenoid.
    There is also a small white terminal block in the same area with red and white wires going too it this also is a weak point
    #5