990 cutting out

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by lopealong, Dec 21, 2013.

  1. lopealong

    lopealong Adventurer

    Joined:
    Jun 15, 2010
    Oddometer:
    68
    Location:
    NSW,AUS
    my 2010 adventure was cutting out when trying to engage 1st gear,but not every time.thought it must be the sidestand switch so replaced that,no difference.While sitting on the bike with the motor going I've came to the conclusion that the bike was cutting out every time l turned the handle bars to the right,regardless if the bike is in gear or not.checked for pinched or loose wires,at this stage cant see any obvious faults.Any other owers came across this
    #1
  2. Grayjet

    Grayjet Ride on!

    Joined:
    Jun 14, 2008
    Oddometer:
    497
    Location:
    Va Beach
    This drove me nuts for a few weeks. I finally tracked it down to a broken wire. The wire which leads from the ignition switch to the wire bundle area behind the head tube (under the storage area), was the culprit. You can see the busted green wire in this photo:

    <a href="http://s994.photobucket.com/user/grayjet/media/Brokenwire1.jpg.html" target="_blank"><img src="http://i994.photobucket.com/albums/af64/grayjet/Brokenwire1.jpg" border="0" alt=" photo Brokenwire1.jpg"/></a>

    I had to split the black casing covering the green and orange wires to find it.

    <a href="http://s994.photobucket.com/user/grayjet/media/IMG_0679.jpg.html" target="_blank"><img src="http://i994.photobucket.com/albums/af64/grayjet/IMG_0679.jpg" border="0" alt=" photo IMG_0679.jpg"/></a>

    This part is the bottom of the ignition switch (where you put your key), under the top triple clamp. Even though you can easily remove this part from the ignition lock, you can't buy it alone from KTM. You have to shell out $300 for the entire ignition module to get this piece.

    So my neighbor soldered it back together for me, and the next trip out, it did it again. I re-examined the broken wire, and it had broken again at the end of the solder. Apparently soldered wires can be brittle. Not good for this wire that is constantly flexing with every turn of the handlebars. I cut out the soldered area, and replaced it with a butt connector. I am sure the electrical gurus out there are groaning, but it has been working great for over 5,000 miles with some decent off-roading, so I am good with it.



    #2
  3. lopealong

    lopealong Adventurer

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    Jun 15, 2010
    Oddometer:
    68
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    NSW,AUS
    Thanks Grayjet,l Think your on the right track .l just went and jiggled the wiring harness from the ignition switch with the ignition on and sure enough it starting going on off on off.I'll pull it apart tomorrow and have a better look
    #3
  4. gefr

    gefr Life is a trip

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    Nov 26, 2005
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    4,615
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    East Med, Greece
    The tie wrap keeps the cables sharply curved but still, so there is no flexing movement that would finally cut the cables.
    Cheers.
    #4
  5. Zuber

    Zuber Zoob

    Joined:
    Sep 28, 2004
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    2,614
    Location:
    Main Street, Shedd, Oregon
    I had the same problem and for 2013 KTM now shows you can buy just the switch part, which included the immobilizer switch, but not the lock, for about $100. 60111066050 INSERT IGNITION LOCK.
    #5
  6. Grayjet

    Grayjet Ride on!

    Joined:
    Jun 14, 2008
    Oddometer:
    497
    Location:
    Va Beach
    Hey, that's good to know; thanks for the info. I'll bet it is the exact same part for both years, though the 2 parts schematics are different (at least the schematics at Rocky Mountain ATV & MC are different).

    Cheers,
    Lance
    #6
  7. lopealong

    lopealong Adventurer

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    Jun 15, 2010
    Oddometer:
    68
    Location:
    NSW,AUS
    Finally got a chance to have a look at the wiring{Christmas held things up}.sure enough,the green wire had split right on the bend,exactly the same as in the picture.dont know if this a common problem,mine has 63k on it.thanks for the info,no way l would have found it myself.
    #7
  8. Grayjet

    Grayjet Ride on!

    Joined:
    Jun 14, 2008
    Oddometer:
    497
    Location:
    Va Beach
    Hey, Lope. Glad to help. I'm not sure how frequent it is, but I only had about 10k on mine when it broke. I had to get towed out of the woods by a TW200. Now that was humbling.

    #8
  9. JoeMongo

    JoeMongo ¿Por dónde?

    Joined:
    Dec 9, 2004
    Oddometer:
    670
    Location:
    SF Bay Area, not exactly dirt moto heaven
    Now that is just funny. Got any pictures?
    #9
  10. KtmPedro220

    KtmPedro220 Adventurer

    Joined:
    Oct 19, 2012
    Oddometer:
    69
    Location:
    Wales, UK
    Good to know.
    #10