Electrical woes on KTM

Discussion in 'Thumpers' started by johan, Dec 16, 2007.

  1. johan

    johan Been here awhile

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    I've got some issues with a fuse on my KTM 640Adv (the one for the dash-board and turn signals).

    After changing it, it burns after 30 seconds or so. Any idea where to start looking (and for what should I be looking)? I've essentially never diagnosed electrical issues before but don't mind getting my hands dirty

    /johan
    #1
  2. Donkey_Kong

    Donkey_Kong Banned

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    You need an ohmmeter and a test light. Unplug the wires from that fuze where they conect in the dashboard and see if they are still grounded. If they are then start looking for the ground. That's where I'd start.

    If that's not the case then start looking after those connectors.
    #2
  3. strongbad

    strongbad Been here awhile

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    What Donkey_Kong said.

    You'll need schematics and a hand full of extra fuses. Remove turn signals one-at-a-time and see if the fuse still blows. Just keep removing items from the bus protected by that fuse until the fuse stops blowing. The last item removed has the fault in it.
    #3
  4. jamesdemien

    jamesdemien Been here awhile

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    Check the wire for you cooling fan... Mine fell on the header melted through and when the temperature gets up enough to turn the fan on it blows the fuse. Turn signals, dash lights, instruments and the fan are all on the same fuse.

    As an easy fix--because removing the fan looked like a bitch--I cut the shrink wrap off of the wires just past the melted part wrapped each one in heat shrink then wrapped both of them in heat shrink and zip tied it safely out of the way...

    Anyway, I'd look there first.
    #4
  5. Marvin_ADV

    Marvin_ADV Been here awhile

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    Sometimes wires will get pinched and cause the fuse to blow. I had the problem in the wire bundle near the steering head. Everytime I turned to the left it would blow because it was shorting out. You may want to check there.
    #5
  6. jamesdemien

    jamesdemien Been here awhile

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    so did you figure it out?
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  7. Kawidad

    Kawidad Long timer

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    Agreed, it sounds like a grounded hot wire, either pinched or melted.
    #7
  8. johan

    johan Been here awhile

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    Thanks guys for all the suggestions.

    Too bitchin' cold to work on this now though, must wait until I visit my father and can work in his garage
    #8
  9. SFmax

    SFmax Guest

    Yup, pull the front fairing off and go through the loose, (unbound) wires under the dash. Sounds like something was rubbing together and probably created a short. You should be able to see/feel it.
    #9
  10. jamesdemien

    jamesdemien Been here awhile

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    If it dies when its cold out then ignore my suggestion unless you're running it on the center stand for more than 5 minutes the fan shouldn't kick on.
    #10
  11. johan

    johan Been here awhile

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    I forgot to close this support ticket...

    Some week later when I made an effort to solve the problem, I could not reproduce the problem, the fuse did not burn any longer, and I haven't had any problems for 1000km or so.

    I am just waiting for this to return though, on a larger scale, when I am out in the middle of nowhere
    #11
  12. meat popsicle

    meat popsicle Ignostic

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    Not that this would help if you had a serious problem that kept blowing a fuse, but you can now convert your fuses to "circuit breakers" that have manual reset buttons:

    http://www.snapaction.net/index.htm?include=mx5.inc
    [​IMG]

    Maybe they are worth it just so you don't have to go out and buy more fuses.

    Just looking for a place to put this link out there to start a discussion :ear

    I haven't found too many fuse-related woes type threads, but I only looked for a minute:

    http://www.advrider.com/forums/showthread.php?t=335666
    #12
  13. Wylie

    Wylie Back in the saddle again

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    Thanks for posting these MP, I might have to buy into them.:thumb
    #13
  14. jachard

    jachard Been here awhile

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    All, I had the exact same problem on my 640e and now it has 'migrated' to my headlight fuse. I had the same symptoms as johan and then the mysterious disappearance as well. I'm going to check the headlight wires as well as the switch to see if I see anything.

    This is most frustrating on a bike with only 1800 miles on it...

    James
    #14
  15. for-a-song

    for-a-song adventure

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    Yup,
    I just bought a 02 LC4 six days with 1700 miles on it. I haven't even been able to ride it yet and the Neutral light, Horn, and blinkers all just went out, I have only started the bike 3 times since I bought it......

    I am pissed.
    #15