03 KTM 640 Adv -- Electrical Problem

[alpiv]

I was our riding and had to turn around (missed a turn), turn the bars to the left to make a left turn, felt resistence and as I cleared the resistence, the bike shut off.
Turn the bars streight, it would start and run fine. Yet when I turn the bars far left, about the time the keyswitch would pass the frame it would shut off --Like I was grounding the system out.

Anyone else have this problem ?

[gaspipe]

Originally Posted by alpiv

I was our riding and had to turn around (missed a turn), turn the bars to the left to make a left turn, felt resistence and as I cleared the resistence, the bike shut off.
Turn the bars streight, it would start and run fine. Yet when I turn the bars far left, about the time the keyswitch would pass the frame it would shut off --Like I was grounding the system out.

Anyone else have this problem ?

Wonder if the ignition switch leads pulled out of the soldered contacts.

It happened to me on the CD Ride. Check the pigtail coming from the bottom of the switch. It's about a foot long, and goes into a molex connector on the right side fairing brace.

LVR resoldered them in the field.

Check it out and let us know.

[fire_strom]

If it turns out not to be what Gaspipe mentioned you might check the choke cable. mine got hung up on somthing so that it'd die abruptly when the bars turned full lock. do your lights shut off or just the motor?
scott

[billy bee]

Originally Posted by fire_strom

If it turns out not to be what Gaspipe mentioned you might check the choke cable. mine got hung up on somthing so that it'd die abruptly when the bars turned full lock. do your lights shut off or just the motor?
scott

I had the same experience with the choke cable...

bb

[jfn68]

my 99 adv did that,it broke a wire about 100mm forward of the ignition switch,it was either white or yellow,on the rhs.

[alpiv]

Originally Posted by fire_strom

If it turns out not to be what Gaspipe mentioned you might check the choke cable. mine got hung up on somthing so that it'd die abruptly when the bars turned full lock. do your lights shut off or just the motor?
scott

No, shuts everything off and I have to turn the key off then back on to get it to start..
I broke the front end down this evening and could not find anything loose or frayed something.

Bike starts fine and still runs with bars turned..

I checked for obstructions or pulled wires with nothing showing..

Gaspipe: Which wires came loose on yours?

[gaspipe]

Originally Posted by alpiv

Gaspipe: Which wires came loose on yours?

You have to disassemble the switch. The black plastic bottom part of the switch has a hole in the middle where the wiring pigtail goes into the switch. Inside there is where the wires pulled off the soldered terminals.

If your IMO goes all wonky and dies or is blank, and the motor dies like you turned the ignition off, I am betting that's what it is.

A pic from the ride report, page 20:



HTH,

Bruce

[OldnoGPS]

You should whip the guy who sold you that thing! (Kidding, it was me.)
FYI - I never had it do that to me. Or anything else, bike was totally reliable.
My old DR650 would cut off turning left like that from the choke as was mentioned. With the tank off it didn't do it, just enough extra stretch with it on that it did. Rerouting fixed it but it was hard to find, I thought sure it was electrical.
Gaspipe surely knows more than me about the thing. I do know that what I saw of the harness/connectors on that bike were all as new and clean.
Sorry it's being cantankerous.
Is the clutch interlock still connected, maybe being pulled on? (I never removed the interlocks, don't know why - first thing I did on my DRZ and XR).
Ted

[RedDread]

Originally Posted by gaspipe

Wonder if the ignition switch leads pulled out of the soldered contacts.

It happened to me on the CD Ride. Check the pigtail coming from the bottom of the switch. It's about a foot long, and goes into a molex connector on the right side fairing brace.

LVR resoldered them in the field.

Check it out and let us know.

This just happened on my 03 640 adv. I bought the new switch but am having a hell of a time with the tamper resistent bolts attaching it to the fork crown. Suggestions?

[gunnerbuck]

Take a Dremel and grind a slot in them for a screwdriver...

[sac]

I have an 07 adventure that will occasionally blow the ignition fuse. The problem begins by the bike not wanting to turn over when i hit the starter. But will do so on the next press of the magic button. First time it blew it left me overnight in Skagway until i figured it out. Not an entirely bad place to be stranded but has anyone experienced this and/or have a really good idea what i should start looking at?

Thanks

[wrk2surf]

seems like too new of a bike...longshot guess but maybe the sprag is going bad and when it gets loaded its popin the fuse... first check all easy connections IE starter lead,battery, ground etc.. and if your not good at electronic diagrams and using a meter find a good freind that does and trace the issue. I guess you should start by taking off the faring tank and seat though...

good time for some yearly loving for everybodys lc4!

[svenb]

See the attached image. I had have some problems during this season on my 2003 640 Adv.

Quite often It will not start, similar to no juice in the battery. Displays shut´s off, starter klicks. If I use decomp I might get it started. Otherwise I have to kickstart. Then it works fine for a day or two. Strange

On my latest trip it was more serious. When I was as far from home I could be it wont start or let me kickstart it. I had to use cables from a friend.

Next problem was when I tried to use Hi beam, It just shut off the whole bike. No power at all, cables again.

If you look carefully, you can see that Blue and Red White are not soldered and they has been loose for a while.
According to wiring diagram, those cables are not in use, but what if they touches another cable?

Any ideas?

[alpiv]

I'm wondering if this (again) is not the cause of my current problems...
Everything works on the bike, except no spark.
Light, turn signals, break lights work as well as the engine turns over, yet no spark.

Coil, pulse coil, stator have all been replaced.

Still no spark..

Who has a wiring diagram I can look at?

[ChrisC]

Originally Posted by alpiv

Who has a wiring diagram I can look at?

Check your PM...