2010 KTM 990 Adventure

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by PeenieWallie, May 4, 2015.

  1. PeenieWallie

    PeenieWallie KTM Adventure 990

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    Jun 11, 2014
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    Morrison, Colorado
    I have a 2010 KTM 990 Adventure. I bought it new and put 25,000 miles on it. I've had some electrical issues with it on and off. I replaced the battery last summer in Prince George, B.C. in a Wal-mart parking lot. Then, a few weeks ago, it wouldn't start. I pushed the start and it just clicked and then wouldn't turn over at all. Charging the battery solved the issue.

    Yesterday, I was riding and killed the bike. When I tried to start it again, it just clicked and nothing happened. I roll-started it down a hill, and it started, but the instrument cluster went haywire. The analog tach kept cycling from 0 RPM to 12,000 RPM. The numers on the LCD digital display kept showing all 8888 for speed, odometer, etc. All of the lights on the instrument cluster would light up. Then go off. The instrument cluster kept freaking out like this, cycling back and forth until about halfway home, at which point it settled down and seemed to work fine.

    I'm guessing that my battery died on me? I'm guessing that the alternator isn't charging my battery right? Does anyone have any tips/suggestions/feedback on this? It's driving me nuts. I already took it to the KTM dealership last year and they said the alternator was fine. I'm at witt's end with this thing.
    #1
  2. Mr Head

    Mr Head Adventure Hippie

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    Check the wires from the ignition into the guts and the plastic panel at the right side of the steering head.
    The plastic pinches the wires and eventually they break/short.

    Where in Morrison?
    I used to live south of there. I traded the snow thrower for full freeways.:lol3
    #2
  3. Zuber

    Zuber Zoob

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    check your install job on the battery. Often, the replacement batteries have the terminals recessed back from the edge of the battery case. The original is flush. You have to re-route the battery cables to lay flat on the battery terminals. OR, they are just loose.
    #3
  4. PeenieWallie

    PeenieWallie KTM Adventure 990

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    Mr. Head - OK. Many thanks. I will check the wires as you describe. I live up North Turkey Creek. My mailing address is Morrison, but I'm technically in unincorporated JeffCo. Are you in SoCal now? Have you driven down to Cabo?

    Zuber - I will check battery terminal leads as well. Thanks for your feedback.
    #4
  5. Mr Head

    Mr Head Adventure Hippie

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    Yes, Orange County.
    Never been to Cabo. Too much work and stuff.
    We lived south of 285 and just east of C470. Used to ride up fro breakfast in Kittridge.
    Same deal. Unincorporated.
    I don't miss the snow.

    #5
  6. Hill Climber

    Hill Climber Been here awhile

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    I've had less than one year old batteries fail at the poorest of times (no joy with a flameout on a single track hill climb and the go button doesn't work) I now only use Yuasa, as they consistently give me at least 3 or more years of service. ( I replace at 3 years and use the old one as a bench battery)
    I'd suggest you start by taking the battery out, put it on a slow charge for 24 hours and test it the following day. Maybe take it to any bike shop and have them put a load test on it. Shouldn't cost you anything to do the test.
    Get this out of the way, and if the battery tests OK, then move onto ensuring all battery connections are super shiny clean and tight. I think it's rare for an alternator give up at 25,000 miles.
    Looking forward to you telling us what the problem is/was.
    #6
  7. PeenieWallie

    PeenieWallie KTM Adventure 990

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    Roger that. I'll follow up with my results. The battery is on a trickle charge right now. I'm going to leave it on over night. I'll try to connect it all up tomorrow after work and go for a ride to test it out.
    #7
  8. PeenieWallie

    PeenieWallie KTM Adventure 990

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    You should drive down to Cabo if you get a chance. I drove there from San Diego and back. Beautiful ride, but a long way between gas stations. Almost ran out of gas in the Punta Prieta desert. Not a good move.
    #8
  9. lopealong

    lopealong Adventurer

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    Jun 15, 2010
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    Location:
    NSW,AUS
    Same as mr head,the green wire from the ignition was shorting out everytime the bars were turned to right,if the battery turns out to be ok,might be worth checking those wires
    #9
  10. DesertSurfer

    DesertSurfer Tail sprayin

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    The voltage regulator/ rectifiers can/do go out on these bikes. Causes vary but one symptom is overcharging and frying batteries. If you have been running with a bad battery that's been pulling a lot of juice from your charging system it can over heat and fry your VR/R. That could be part of your problem. Check your system for charge.
    #10
  11. PeenieWallie

    PeenieWallie KTM Adventure 990

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    So, yesterday, I put the battery on a trickle charge at 2 amps for 24 hours. Then, this morning, I hooked the battery up to the bike, and drove it to work and back. Seems to be working fine, but I'm not clear that I've solved the underlying issue.

    I still need to check to see if there's a short in the wires I guess. Also, there is a little plastic panel that covers the battery that I think I left off some time last summer. Not sure if that's an issue or not.
    #11
  12. Hill Climber

    Hill Climber Been here awhile

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    In your first post, you said the bike wouldn't start after stalling it (starter just clicked -- sign of a dead battery) You got it going by rolling it down a hill, but the electronics were sporadic, but eventually they stabilized. A clear indicator the charging system is working.

    It appears to me that your battery is failing by not being able to hold a full charge. The easiest, cheapest and first test you should do is test the battery for capacity.

    The only way you can truly test a battery to determine its ability to maintain a charge is to test it with a load tester. Any bike shop should have one and test it for free (after charging it to full). Once you've determined the battery is in good shape, you can move onto checking the charging system. (I'm assuming you've cleaned the terminals and connectors super well and shiny)

    If you aren't close to a bike shop with a load tester, then take the battery out, charge it up fully. Let it sit for a short time then test the voltage with a multimeter set to DC volts, with its scale set to at least 2 decimal places. Leave it connected to the battery for at least 10 minutes and see if the voltage slowly drops, i.e. 13.25, 13.24, 13.23, and so on. If it drops slowly, chances are your battery has a bad cell. If the number i.e. 13.25 stays rock solid, then chances are the battery is in good shape.
    Next, put the battery in the bike and hook it up. Connect the multimeter to the battery, then start the bike while watching the voltmeter. If the voltage drops to below 9.5 volts while cranking it over, then I'd suspect the battery is faulty. (Find a dealer with a battery load tester).
    When the bike fires up, rev it up a bit and watch the voltage again. It should read 13.5 to 14.5 volts. If it is below 13.5, then I'd suspect a charging issue, maybe the regulator or a loose connection at the regulator.

    BTW, did you put the battery on a battery maintainer (battery tender) over the winter months while it wasn't been ridden? If you didn't, and if the battery isn't a quality battery to start with, the prolonged non-use may have taken it's toll on it. (Generally, Chinese batteries aren't considered quality batteries....)

    The battery tender I'm referring to should have a 4-step charging program (Initialization, Bulk Charge, Absorption Mode, Float Mode)

    Hope this helps....
    #12
  13. PeenieWallie

    PeenieWallie KTM Adventure 990

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    Here's what I don't get though....The battery that I'm currently using came from Wal-Mart, but I bought it last summer in August. So, that means that the battery my bike came with died last summer. I replaced it. and the battery I replaced it with didn't last 8 months.
    #13
  14. Hill Climber

    Hill Climber Been here awhile

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    Was the battery that failed last summer the original factory battery? If it was, it was at least 4 years old. About the life expectancy of a quality battery.
    The Wal-Mart battery, I suspect, may be a Chinese battery. Some of these you win, some you don't. I've bought a few Chinese batteries in the past, the last one didn't make it 3 months. I now pay the extra $$$ for a quality one and my preference is Yuasa. That's what it came with, that's what I replace it with. I replace at the 3 year mark.
    Do the load test.... this way you'll know for sure if it's at fault or not. Call your local Wal-Mart and see if they'll do a load test on it.
    If it fails the test, you can probably have it replaced on warranty, but you may run into the same problem down the road.

    Cheers,... :)

    #14
  15. PeenieWallie

    PeenieWallie KTM Adventure 990

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    Tried to start it this morning and got nothing. Plan is to replace the battery (again).
    #15
  16. PeenieWallie

    PeenieWallie KTM Adventure 990

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    Took my battery into Wal-Mart and had them check it just now. The battery I have is an EverStart ES9BS. The guy tested it and said the following:
    Battery Test Results
    Good Battery
    Voltage: 12.92 V
    Measured: 228 CCA
    Rated: BTX9(BS)
    Temperature: 75F
    Battery meets or exceeds required standards.
    Average life in area 59 months.

    So, I think something is wrong with the KTM, not the battery. At this point, I'm taking it into the KTM dealership, I'm thinking.
    #16
  17. Hill Climber

    Hill Climber Been here awhile

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    You tried to start the bike this morning and it didn't start, but yet the battery tested good?
    If this is the case, then it's not the regulator or alternator causing the problem.
    Could be a connection problem at the starter, or something within the starter.
    In your first post, you mentioned you'd been having some electrical issues last year before you replaced the battery. Make sure you mention this to the mechanic at the dealership.
    I'm curious as to what the problem will be diagnosed as.....
    #17
  18. PeenieWallie

    PeenieWallie KTM Adventure 990

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    You and me both.
    #18
  19. outbacktaz

    outbacktaz outbacktaz

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    :ear:lurk
    #19
  20. Hill Climber

    Hill Climber Been here awhile

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    Did you get the problem diagnosed?
    #20