Need some HELP from the collective genius of this site

[Kenbike]

I agree your battery may have went bad due to a different issue. Follow the test outlined in the links. If you do not a volt/omh meter you will need to get one. If you have no experience with auto or bike systems first check for bad connections and all grounds connections to metal. Use dielectric geese when you reconnect because this should be done anyway. If you don't locate the issue get help from a experienced auto electric guy. These KTM's have more than their far share of wiring issues!

[stimmer6253472]

Yeah I got all of the tools I would need. Was just hoping it was some known issue instead of some random wiring fault.

The valves need checked as well so I am guessing some weekend I will tear into both jobs. Below freezing here so I guess it happened at a good time.

Jim

[Ramv]

Not fuel locked? Sixth gear roll it backwards. I had mine do it once after hauling it 500 miles.

[stimmer6253472]

Originally Posted by Ramv

Not fuel locked? Sixth gear roll it backwards. I had mine do it once after hauling it 500 miles.

Hmmm... Interesting, never heard of fuel locked. Just put it in 6th and roll it back enough to rotate the engine?? After which it will turn over.
Any more details? Definitely give it a try.
Jim

[HeatXfer]

Doesn't look like power supply issue, it sounds like the starter relay is dropping out. Possibly a loose connection somewhere between the battery and the starter relay.

If you haven't already done so, pull and inspect all connections between the battery and the starter relay. It would seem there is an interruption of power along that path. A loose connection can cause a higher than normal amp draw on a circuit, which in turn can cause voltage drop below a component's rating, If the starter relay has a minimum operating voltage of 10.5volts, and you see an intermittent drop to 8.5 volts when the starter button is pushed, the relay will drop out, the voltage will return to +12 and the whole cycle starts all over again.

[Bugman98]

A bad battery cable perhaps? Or one that is loose?

[stimmer6253472]

Originally Posted by HeatXfer

Doesn't look like power supply issue, it sounds like the starter relay is dropping out. Possibly a loose connection somewhere between the battery and the starter relay.

If you haven't already done so, pull and inspect all connections between the battery and the starter relay. It would seem there is an interruption of power along that path. A loose connection can cause a higher than normal amp draw on a circuit, which in turn can cause voltage drop below a component's rating, If the starter relay has a minimum operating voltage of 10.5volts, and you see an intermittent drop to 8.5 volts when the starter button is pushed, the relay will drop out, the voltage will return to +12 and the whole cycle starts all over again.

This seems the most likely. I originally inspected the area and everything was clean and appeared tight. I figured I would start there.
Jim

[HeatXfer]

Jim,

I found this post.

Hope this helps

Chris

[stimmer6253472]

I know, I know two months before I dug into it but If finally did today and I got her running in about 15 minutes. My only excuse is this isn't the best time in Missouri to ride.

First off it wasn't the battery. Basically I just took the starter relay off and greased all the connectors and fuses and put it back together and it fired right up. I thought that was somewhat of a long shot as mine looked very clean compared to the others I have seen posted here. However, I guess something wasn't right.

Thanks for all of the help. I guess it isn't always the battery.

BTW I bought an OEM battery in '08 when I bought the bike used with a bad battery. So far I have 3-4 years with 35,000+ miles with no battery problems. I do keep it almost always on a tender when in the garage.

Jim