Ignition Harness at the Steering Head Broke

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Luv2putt, Dec 18, 2011.

  1. Luv2putt

    Luv2putt Confused

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    Has anyone experienced the ignition wire harness breaking at the steering head/plastic cover due to not enough slack on a 990 ADV? I was looking up a few sites and can't find just that short harness. Is the short harness sold separately? I re-connected and heat shrink coated all wires, but it looks like my repair will be a little stiff and I hope it doesn't happen again. I'll do my best to supply the harness with flexability so we'll see what happens.
    #1
  2. AdvGa

    AdvGa Long timer

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  3. Weldit

    Weldit Been here awhile

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    why was there not enough slack - handlebar risers installed ?
    #3
  4. Luv2putt

    Luv2putt Confused

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    There was plenty of harness behind the plastic cover, wish I would have known. I would have pulled out more harness to create the slack. I have a Scotts top triple clamp and steering stabilizer installed, but the ignition appears to be in the same location as a stock unit. I was reading http://www.ktm950.info/how/ktm_950_issues.html and almost all the way down the page is this...

    Wiring problems:

    2005 - 2007 and 2010 Adventures. There were a rash of bad wiring harnesses with broken wires inside the insulation near where the bend is made for the steering head. It is suggested that owners check that the harness has enough slack in this area and re-route those that are found to bind. Random bad crimps have been found on some 2010 bikes.
    #4
  5. frog

    frog Long timer

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    Yup. Happened to me in Baja. Ended up testing the wires together for the rest of the trip.
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  6. Afry

    Afry Why hike?

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    Being an old racer I sometimes think why not go Orange? Then these threads pop up and remind me simple is good. Maybe not as fast but much cheaper and more saddle time on my Klr......okay, flame away....
    #6
  7. Weldit

    Weldit Been here awhile

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    OK you asked for it !
    what there are no wires up to ignition switch on a KLR ?
    whats up with the "Doohickey" on KLR ?
    OK thats enough :evil
    #7
  8. Whip

    Whip Onward through the fog

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