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Old 06-05-2014, 09:02 AM   #91
Gnarly Adventurer
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Joined: Feb 2013
Location: Lake Havasu, AZ
Oddometer: 441
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.
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Old 06-05-2014, 09:18 AM   #92
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Joined: Jul 2010
Oddometer: 979
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.
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Old 06-05-2014, 10:08 AM   #93
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Joined: Sep 2005
Location: Fort Collins
Oddometer: 8,867
Originally Posted by johnno950 View Post
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.
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.
We don't stop riding because we get old, we get old because we stop riding.
"Wisdom is knowing what to do next, Skill is knowing how to do it, and Virtue is doing it"

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Old 06-09-2014, 04:24 PM   #94
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Joined: Aug 2012
Location: Victoria, B.C.
Oddometer: 27
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.
Current: 2012 KTM 990R
Past: CT 90, KX 125, IT 250, Sonic 500, XS 1100
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Old 07-14-2014, 04:39 PM   #95
Joined: Dec 2013
Location: Southern Armpit
Oddometer: 1
Pissed Yup!

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.
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Old 08-28-2014, 09:55 AM   #96
NeptuneTriton OP
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Joined: May 2013
Oddometer: 181
Another victim claimed by the pinched ignition harness. Keep checking your bikes fellas!
America will never be destroyed from the outside. If we falter and lose our freedoms, it will be because we destroyed ourselves.
-Abraham Lincoln

Kronreif, Trunkenpolz of Mattighofen - Model 990, Adventure Baja
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Old 09-06-2014, 05:45 PM   #97
ex halligan hooligan
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Joined: Mar 2010
Location: Off-Rhode Island
Oddometer: 655

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.
Ernie Young
'12-KTM-990adv '02-KTM-400exc '81-HONDA-XL185s motorcycle drawings * Turf & Surf: NE-NB 2011
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Old 09-23-2014, 07:55 PM   #98
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Joined: Jul 2010
Location: Hillsboro, OR
Oddometer: 1,078
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?
2010 KTM 990 Adventure-Nuclear Fusion Powered
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Old 10-13-2014, 08:49 AM   #99
Sit there, turn that
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Joined: Aug 2001
Location: Great White North
Oddometer: 4,423
This thread really should be a sticky

I became friends with someone just because they rode motorcycles from no-place to no-where.
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