KTM 990 Adventure Baja Ignition Wiring Harness Bad Installation - Check Your Bikes!!

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by NeptuneTriton, Feb 28, 2014.

  1. Trail Joe

    Trail Joe Adventurer

    Joined:
    Feb 9, 2011
    Oddometer:
    18
    Location:
    Washington
    I checked mine yesterday and after pulling back the sheathing found one wire was pinched but no actual damage. This is on 2013 Baja with 4000 miles. Trimmed the plastic and now it moves freely. Thanks for the tip to check this as I don't know how long it would have lasted.
    #81
  2. 2kool2be4gotten

    2kool2be4gotten Adventurer

    Joined:
    Oct 7, 2008
    Oddometer:
    40
    Location:
    Waterloo, ON
    From what i've see there are two possible failure points:

    1) where the black cover contacts the frame (wires pinched)
    2) where the bundled wires bend when the bars are turned (wires fatigued)

    My '12 Adv did not show any sign or wear at the black cover / frame - however, the wires were 'kinked' to the point of fatigue where the bundle made the 90 degree turn under the triple clamp.

    Be sure and check both locations for signs of wear.
    #82
  3. 05magmn

    05magmn Been here awhile

    Joined:
    May 1, 2013
    Oddometer:
    233
    Location:
    S.E. MN
    I checked my 2013 baja last week when I picked it up! The wires and plastic gaurd where loose enough for the wires to move freely! No pinching!
    #83
  4. grant22

    grant22 Been here awhile

    Joined:
    Feb 22, 2013
    Oddometer:
    602
    Location:
    Lake Havasu, AZ
    Well, I didn't know about this thread. At 9000 miles finally, my '13 990 started cutting out as I left my driveway for a 300 mile ride.

    Inspected today, found the orange wire roached, repaired and opened up the right plastic piece a bit. Problem solved but will be ordering a new switch harness.

    I did this while ONLY removing both upper fairings.
    #84
  5. minerbill

    minerbill Emits Methane

    Joined:
    May 3, 2010
    Oddometer:
    374
    Location:
    NW Colorado
    I had the upper fairings off while installing some bar risers and was able to trim the offending piece. I used a pair of needle nose pliers to roll the offending piece out of the way and cut it off with some tin snips. Not pretty but it got the job done and you can't see it anyway. The wires move freely now.
    #85
  6. two trackin fool

    two trackin fool Long timer

    Joined:
    Nov 6, 2010
    Oddometer:
    1,598
    Location:
    Mobile with any Luck if not Michigan
    yup I just repaired the wire flex at the mount for the headlight . Every hard left with the forks rubs the harness.
    #86
  7. DirtyADV

    DirtyADV Long timer

    Joined:
    Jan 13, 2007
    Oddometer:
    3,074
    Location:
    SWEDEN, SkellefteƄ
    A friend bought a 2006 990 Adventure with about 15 000 km on it and sure ignition lock pinched on that one also.

    Helped him look it over when purchasing it.

    /Johan
    #87
  8. HellSickle

    HellSickle Scone Rider

    Joined:
    Sep 19, 2005
    Oddometer:
    10,473
    Location:
    Fort Collins
    This is exactly what I had mine fail yesterday. Broken wire just below the ignition switch. Early symptom was sporadic dying when I was maneuvering the bike in close quarters. Yesterday it finally opened completely. I soldered a connection & bound everything in plastic wire loom.

    While I was there, I cut a corner off the plastic cover to allow the wires room to go into the frame. I recall being puzzled over this when I first got the bike and tore it down.
    #88
  9. up2nogood

    up2nogood Adventurer

    Joined:
    Apr 2, 2008
    Oddometer:
    66
    Location:
    Sydney, Australia
    Had same issue. Wires just snapped at the base of the ignition switch. Have routed a longer set of wires and looped them so the wires don't work harden and snap again.
    #89
  10. RoundOz

    RoundOz Plenty of seasoning

    Joined:
    Jun 10, 2009
    Oddometer:
    1,180
    Location:
    West Nebraska
    Thanks to this thread I found mine pinched the other day...no apparent damage. My reason for posting is that I didn't have time to remove my Safari to do a nice job of fixing it. 2 min with a sharp wood chisel opened up the hole. I will tidy it at my next valve service. No need to put this off and the kink does look bad enough to eventually cause issues in all bikes with a fixed loom and these plastic skirts.

    Sent from my SCH-I535 using Tapatalk
    #90
  11. grant22

    grant22 Been here awhile

    Joined:
    Feb 22, 2013
    Oddometer:
    602
    Location:
    Lake Havasu, AZ
    I finally got my new ignition switch harness so it was time to install it.

    Although I tried cutting back the plastic filler piece, it still seemed the harness didn't want to slip back and forth into the frame as I turned the bars. I cut more and more but it never really slipped, like it should to keep the bending of the wires over and over.

    The harness is lengthy, so just removing the plastic filler pieces would solve the wire bending issue, but the harness would probably flop out.

    I chose to zip tie the harness to the frame, but the zip ties are applied loosely to allow for slippage.

    I have all the confidence in the world now in the harness.
    #91
  12. johnno950

    johnno950 Long timer

    Joined:
    Jul 17, 2010
    Oddometer:
    1,310
    Sub standard layout of the wiring looms etc has been a thing with the ktms for years now,lets hope voncouldntgiveafuck is nearly ready for retirement from the assembly line.
    #92
  13. HellSickle

    HellSickle Scone Rider

    Joined:
    Sep 19, 2005
    Oddometer:
    10,473
    Location:
    Fort Collins
    This particular issue was a design problem, not assembly. Amazing they kept building it this way. My bike started dying intermittently when turning. Imagine if some took a left turn in front of oncoming traffic and had the bike stall? This would be similar to the recent GM ignition switch issue.
    #93
  14. PopQuiz

    PopQuiz Adventurer

    Joined:
    Aug 5, 2012
    Oddometer:
    27
    Location:
    Victoria, B.C.
    My thanks to the OP. Checked mine today and sure enough...pinched and cracked sheathing with a crease in the sheath of one wire, but no apparent damage. Offending piece cut and sanded. It is easy to remove with right fairing off...except for that damn screw falling and ending up somewhere unknown...grrrrr hate when I do that. Luckily I have a good bin of screws and found one that worked.:thumb
    #94
  15. micahsmith50

    micahsmith50 JonSmith

    Joined:
    Dec 15, 2013
    Oddometer:
    1
    Location:
    Southern Armpit
    This just happened to me, on my 2013 KTM 99o, WTF is only 600 miles on it, it's going back to the stealership tomorrow.
    #95
  16. NeptuneTriton

    NeptuneTriton Been here awhile

    Joined:
    May 21, 2013
    Oddometer:
    413
    Location:
    Washington State
    #96
  17. RhodeHazard

    RhodeHazard ex halligan hooligan

    Joined:
    Mar 25, 2010
    Oddometer:
    662
    Location:
    Off-Rhode Island
    I just checked mine while performing another repair and found both wires to the ignition switch had broken through the insulation to bare wire. It was only a matter of time before this would have stopped her dead. Thank you!

    I cut the broken wires out and soldered in new bits. I used wire that is more flexible and provided more length. I also trimmed the upper corner of the blocking plate to provide a bit more flex.

    As I look at the stock setup, I believe the other issue is the rigid wires used in the ignition harness that tend to break rather than bend.
    #97
  18. deeve

    deeve Adventure Lite

    Joined:
    Jul 10, 2010
    Oddometer:
    1,491
    Location:
    Hillsboro, OR
    I checked my wire harness on the right side and the outer loom looks good. No hard kinks or anything. Would the collective suggest making sure the slack stays or open it up to make sure everything is good?
    #98
  19. RumRunner

    RumRunner Sit there, turn that

    Joined:
    Aug 10, 2001
    Oddometer:
    5,393
    Location:
    Great White North
    This thread really should be a sticky

    DW
    #99
  20. RumRunner

    RumRunner Sit there, turn that

    Joined:
    Aug 10, 2001
    Oddometer:
    5,393
    Location:
    Great White North
    TTT

    And a pic for the trouble...

    [​IMG]

    DW