Neutral Light Always on. '06 640 Adv.

Discussion in 'Thumpers' started by F=ma, Apr 18, 2006.

  1. F=ma

    F=ma Deceleration is Dangerous

    Joined:
    Feb 21, 2006
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    I've read reports of intermitten problems with the nuetral light staying on. And maybe I have got this problem, interestingly it just started after my first service (1000km ), so I'm wondering if the dealer could have cause the problem. The light did go off on its own once.. but now its stuck on again. Anyone know where this sensor is? The dealer changed my front sproket ( from 16 to 15 ) I wonder if a sensor or sensor cable could have been damaged? The bike has about 600 miles on it.

    Any tips on what is wrong, is this common?
    #1
  2. DRZmaui

    DRZmaui Been here awhile

    Joined:
    Dec 9, 2005
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    112
    Sounds like switch is disconnected, or grounding out. Or it could be stuck in the off position. The Neutral light comes on when disengaged.

    You can find the switch in front of the engine oil filter.
    Let me know if this helps. I just replace mine. Had to wait 3 weeks for the part
    #2
  3. ChrisC

    ChrisC Amal sex?

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    Creep's replying...... wait for it :evil
    #3
  4. creeper

    creeper Still alive...

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    Item 17, (center left) is the neutral switch, located just ahead of the transmission sprocket. This routes thru a multi-plug (30) and on to 48, a diode.
    Item 40, a clutch interlock switch also routes to this diode.

    Voltage flow is thru the starter button (9), to the aux relay (42).
    The diode (40) must be closed (grounded) by the clutch interlock (40) or the neutral switch (17) for the aux relay to become energized, closing the contacts.
    When the aux relay closes voltage flows to the main starter relay (37), which energizes, closing the contacts, then voltage can flow to the starter itself.
    The neutral light comes on when (I assume) the diode internal curcuit is closed via the neutral switch.

    At least thats the way it looks to me... but I could be way off.

    [​IMG]

    Not all circuits are indicated. To view each subsystem, click here.

    C
    #4
  5. Phoenician

    Phoenician Been here awhile

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    Thats an easy fix... Jack up the horn and put a Honda under it. Should fix your problem and any other problems in the future.....:D
    #5
  6. creeper

    creeper Still alive...

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    Thats not fair... I could have said fuck it and walked away ya' know.

    Well... I could have. :D
    #6
  7. ChrisC

    ChrisC Amal sex?

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    Bite us (collectively), Uranus Boy....

    Fuckin' n00bs.... :norton
    #7
  8. creeper

    creeper Still alive...

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    I see a rant coming some day... can't wait. :thumb
    #8
  9. meat popsicle

    meat popsicle Ignostic

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    Get a room you two...
    #9
  10. ChrisC

    ChrisC Amal sex?

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    It's a fuckin' n00b ass prodding contest. What fun.... :cry
    #10
  11. meat popsicle

    meat popsicle Ignostic

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    Thanks man,

    The index needs electrical troubleshooting threads. :thumb

    EDIT: I just noticed that my "get a room" comment now appears to relate to two entirely different individiuals :rofl
    #11
  12. ChrisC

    ChrisC Amal sex?

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    You know I love him dearly, but sharing a room? I don't think so.... :D
    #12
  13. Buckster

    Buckster Banned

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    You would share underpants with the guy you freak!
    #13
  14. ChrisC

    ChrisC Amal sex?

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    Thanks Bucky, ya wanker...
    #14
  15. meat popsicle

    meat popsicle Ignostic

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    [​IMG]
    #15
  16. jrs1100gs

    jrs1100gs n00b to KTM

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    bouqueville, NM
    While in the Eastern section of the TAT last week:D , my 2006 640 Adv developed the oposite problem:cry . Fuse #3 kept blowing whenever the starter button was pushed or the kick starter used. It had left me stranded tow days in a row:eek1 . A KTM dealer in Southern OK (Durant?) tracked down nearly a dozen wires :huh that had worn through in the 7,000 miles I have on the bike. Its running now:freaky , but still no nuetral light, and so I have to hold the clutch to start it.

    There is now voltage on the green wire at the switch by the oil filter. Several of the shorted (and repaired) wires went through the ignition and charging circuits.

    Also, my Garmin GPS is still showing significant variations in voltage supply (bouncing around 13.8V) and occasional total losses of bike-voltage.

    I'll pull the nuetral switch (contact screw) from the engine case and inspect it when I change the oil and check the valves this weekend. I'll follow Creepers guide for the light that was stuck "on". But, What else should I look for?:ear

    I'm disapointed in the frailty of KTM wiring; it reminds me of my old MGB with the Lucas wiring that had to be completely rebuilt:puke1 .

    I'd like to compensate for future wiring problems before starting out on the Western half of the TAT. So, What else should I be looking for in terms of faulty/worn wiring?:ear
    #16
  17. laramie LC4

    laramie LC4 crash test dummy!

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    why do i always miss all the good threads ???? :loaded :loaded

    laramie :beer
    #17
  18. meat popsicle

    meat popsicle Ignostic

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    you didn't see it before it was cleaned up? I don't recall now, but if I commented it musta been bad.

    =============================================================================

    jrs, creeper is your friend on things electrical - he is the only bloke that has made the effort to understand the LC4's wiring and productively comment on it.

    I do recall awhile back a post on KTM Talk (spammed here too?) who's poster found that upgrading the wiring's gauge significantly improved the function of pretty much everything it was attached to, meaning he was indicating the stock wiring harness is pretty near inadequate (or barely adequate - is the glass half full or half empty?). I have never seen confirmation of this by any other, but if you are redoing your wiring harness get an electrician to help you select the appropriate wire gauge for your restoration and let us know if the results are good. :beer
    #18
  19. Luke

    Luke GPoET&P

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    With the bike in gear, there should be voltage on the switch contact. In neutral, there should be no voltage. This is part #17 on the wiring diagram creeper posted above. If the switch checks out, move up to connector #30. It is between the top of the motor near the valve covers and the frame. Look for the green wire with the black stripe. Test the voltage the same way at the connector.

    After that, you have to start hunting down diodes and whatnot. I don't know where they live.
    #19
  20. wolfswork

    wolfswork whereshegone

    Joined:
    Jul 12, 2006
    Oddometer:
    15
    Location:
    Cascadia
    Interestingly I have developed the same problem on my 2001 640 Adventure. The netural light stayed on for awhile and when it did go off it would not come on with the bike in netural. I have also been experiencing tachometer problems once the netural light started acting up. The tach works fine most of the time but will occasionally loose power momentarely and then start up again. While this is happening the tripmaster info in bouncing back and forth between my current speed and something about half of what I am actually going. Must be a short but I haven't found it yet so out to the garage to look some more. Thanks for your suggestions.
    #20