Kick-starting LC4 with dead battery?

Discussion in 'Thumpers' started by magli, Mar 27, 2007.

  1. Stu

    Stu Buffo Maximus

    Joined:
    Feb 4, 2004
    Oddometer:
    955
    Location:
    Eastern YahooLand
    Just put on the older CEV switch for the 640s. It works fine. I plugged on into a 625 SXC. Straight plug in and everything worked & was properly color coded. Here is a picture of one installed on my new '07 525 EXC.

    This is a straight plug in and everything on the switch worked (except the kill button which you can just wire into the existing kill switch on the other side of the handlebar and have 2 of them). The wiring in the CEV switch doesn't match the 525 color code. Not a problem. On the 525 the only thing that did not work stock with the very cumbersome 950 switch that came on the 525 was the small 5W running light bulb in the headlight shell. I don't want it on all the time anyway so good riddance. (The 950 switch is located with a pin. If you file the pin off to relocate it to get more room for the clutch perch but it then spins on the bar. The CEV switch is half the width so the clutch can be repositioned comfortably for your reach and clamps down tightly and won't move.)

    Stu

    Attached Files:

    #61
  2. Stu

    Stu Buffo Maximus

    Joined:
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    You can now clearly see the dot on the top which is the OFF position for the headlight. If you have a dead battery, and the light is in this off position, you should be able to kickstart your bike to life.
    Stu
    #62
  3. BlitzBike

    BlitzBike LC4 Pilot

    Joined:
    May 6, 2004
    Oddometer:
    800
    Location:
    Ft. Lauderdale, FL near Alligator Alley
    Anybody got a part number for the CEV switch??:ear
    #63
  4. Stu

    Stu Buffo Maximus

    Joined:
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    The switch that I installed and that worked has two basic part numbers, one for the upper part and one for the lower turn signal part. There has been some discussion on another thread about the proper part numbers. Whatever. These work. They are:

    CEV headlight switch: 503.11.070.000 about $62
    CEV turnsignal switch: 503.11.029.000 about $51

    Also note that Sicass Racing has a switch assembly that should work. It has an off position for the lights (looking at it on the web) and a turn signal switch for handlebars with hydraulic clutches (narrow). You can call them and ask. It is less money as well.

    Sicass Bar Switch (complete): 26-040
    Phone # 248.625.0187
    www.sicassracing.com
    Ask for Steve or John.

    Stu
    #64
  5. Reinhold

    Reinhold No, not Messner

    Joined:
    Jun 12, 2006
    Oddometer:
    195
    Location:
    Chuck City
    Just ordered a headlight switch (Europe) from Munns. He said that they are available through him.
    Part # 600.11.074.000
    Sixty plus dollars.
    #65
  6. DUKE II

    DUKE II Adventurer

    Joined:
    Sep 8, 2006
    Oddometer:
    12
    REINHOLD, did you receive the KTM headlight switch Part # 600.11.074.000?, and were you able to make it work? Did it plug in, or did you have to run you own wires for the headlight circuit?
    Also, was the switch housing the same color as our USA version?

    Thanks :D
    #66
  7. Reinhold

    Reinhold No, not Messner

    Joined:
    Jun 12, 2006
    Oddometer:
    195
    Location:
    Chuck City
    Plug and play. Looks exactly like the stock one on my 07 640A except it has the light switch. Works like a damn and easy to install.
    #67
  8. DUKE II

    DUKE II Adventurer

    Joined:
    Sep 8, 2006
    Oddometer:
    12
    Very cool :thumb Will have to order one myself!!

    Thanks :D
    #68
  9. earthmover

    earthmover Opinionated, me?

    Joined:
    Nov 11, 2007
    Oddometer:
    225
    Location:
    Kelsall, Cheshire, UK
    How I wish I had read this before wasting an hour trying to fire my 640 after discovering that my battery was flat. Would start off a booster battery, but wouldn't kick or even bump start.
    Checked the battery with a drop tester to find that it is u/s, so bought a new one. The problem I now have is that with a brand new, fully charged battery on, all I'm getting is a continuous clicking noise from the starter relay when I press the starter.
    Any ideas?
    Mark
    #69
  10. cevquit

    cevquit maphead

    Joined:
    Jul 7, 2006
    Oddometer:
    637
    Location:
    At the foot of the mighty Sierra Nevada
    I used to buy into all this "you cant kick it if the battery is dead flat", until thia last winter.
    My Lc4 had an electrical system melt down, and required a rewire. Since I had to muddle my way through removing all the safety interlocks, and other wiring issuses, my battery got worked.
    I have been kick start only for about 5 months now, left foot, right foot, what ever. Its the hardest to start on a cold morning, but i can kick start it within a few minutes now.
    Its all about charging the cylinder,
    This is my refined method for cold starting;
    choke on full
    no throttle
    pull in manual decomp
    kick a bunch (dozen times)
    dont stop let out the decomp and kick hard and fast
    if it doesnt start
    repeat
    I can usually start mine by the third cycle even when dead cold.

    I dont even look for TDC 90% of the time anymore,l just kick it.

    One thing I have noticed, that when your jetting is too lean the lc4 is hard to kick start.
    #70
  11. earthmover

    earthmover Opinionated, me?

    Joined:
    Nov 11, 2007
    Oddometer:
    225
    Location:
    Kelsall, Cheshire, UK
    So why wouldn't mine start down a long tarmac hill in 5th with the engine turning over like a good'un? When I gave up and pushed it home, there was barely enough life in the battery for the neutral light.
    Mark
    #71
  12. GP640

    GP640 Long timer

    Joined:
    Sep 30, 2006
    Oddometer:
    3,449
    Location:
    NW AB
    Call me crazy but...

    My 06 will start with the key turned just out of the lock position. This does not turn on any lights or the dash. I haven't tried it with a dead battery but I'll bet it would work.
    #72
  13. NICO

    NICO Long timer

    Joined:
    May 1, 2006
    Oddometer:
    26,260
    You're crazy.










    And I hafta try that. My battery went bone dead a couple weeks ago after I forgot to turn the key off. Kicked that thing for a good 15 minutes without so much as a sputter. Usually I can get it started with one kick, so it aint out of tune and I hardly need any choke/enricher to start it cold, so it isn't too lean either. (in theory, anyway)

    Would sure love to have it start with no juice aside from it's charging system.
    #73
  14. meat popsicle

    meat popsicle Ignostic

    Joined:
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    14,263
    Location:
    Circumlocution Office of Little Dorrit
    I walked out the garage and tried this with my 03 LC4a. I can't find this spot where the dash don't light up but the bike will start. In the spot between steering lock and off my dash lights up w/out headlights and the starter will turn - but I'd still have to turn the key past off to run.

    I don't have gas at the moment so I couldn't try this and see if a quick turn would keep the bike running. I guess you could run the bike in (is this called?) accessory mode, but I still am leaning towards adding a switch to turn off the headlight(s) while in run mode.
    #74
  15. riverside

    riverside Been here awhile

    Joined:
    Jun 4, 2007
    Oddometer:
    131
    Well, I know about the CEV switch since my 380 and 525 run them. I bought a Euro version of the right hand switch that has the headlight oof/on switch in it from a guy here on the forum. It does not plug into an '02 wiring Harness. Anyone do a retro fit on one of these and know where to splice in? I am guessing this cam off an '05- newer bike and the harnesses are different. Any ideas?
    #75
  16. Rodzilla

    Rodzilla Horny as Hell

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    Feb 23, 2005
    Oddometer:
    1,643
    Location:
    Wheat Ridge Colorado
    I'm trying to retro fit this onto my '01 EXC with HID

    It would not be plug and play on the stock head light.

    Can anyone tell me the wire codes?

    This has a six pin connector and a single lead

    6 pin has White, Red, Brown, Blue, Green and Yellow

    Single lead is Black/Yellow stripe

    Any help would be appreciated
    #76
  17. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

    Joined:
    May 8, 2006
    Oddometer:
    3,043
    Location:
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    Anyone want a good wiring diagram my friend "Sparky" a real live Electrical Engineer and I drew up that features an on/off headlight toggle used for a dead battery kick?

    It's complete, is for an '03 640A, and works.

    PM me your Email addy and I'll shoot you the wiring diagram file in PDF.

    Dirty
    #77
  18. MF1A

    MF1A Ride with the Wind

    Joined:
    Jul 19, 2006
    Oddometer:
    267
    Location:
    Chile....
    maybe if you can figureout how much power ( the minimum power needed) to kick start the engine, then you can bring a small batery like this one for example : http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXTJH4&P=0 i tink 2 of this conected to the batery leads maybe can light the ignition up....i´m not electrical engineer, just that's an idea...but really i do not know why the ktm guys design an adventure bike with this " issue"....it's like......." hey what's going up?" .....my battery's gone...so do the kick start.....nope.....it does not start if the battery is discharged......duh!!! :kboom so..what's the point to have a kick start if the battery is dead.....well seems like i will write a letter to the ktm guys...
    #78
  19. meat popsicle

    meat popsicle Ignostic

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    MF1A,

    the stink is if you disconnect the headlights you can kick start the LC4 with a "dead" battery. Mine was purdy near dead (Odyssey off charger for 6+ months that lit the dash but only giggled when I hit the joy button) and disconnecting the headlight did it for me.
    #79
  20. riverside

    riverside Been here awhile

    Joined:
    Jun 4, 2007
    Oddometer:
    131
    pmed you dirty. I am curious as to what you guys did. I still may attempt to tie in the Euro switch I have. Can't be too bad, it'd just be nice to have a Euro wiring schematic since obviously the ignition switch doesn't control the headlights like on our bikes. I'd like to do it as close to KTMs way as I can. I have wired a few boats and cars and haven't had a fire yet so ????:rofl
    #80