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Old 10-16-2008, 06:02 AM   #16
alpiv OP
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Joined: Dec 2004
Location: Indianapolis, IN
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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?
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Old 10-16-2008, 07:55 AM   #17
ChrisC
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Location: Prescott, Arizona USA Earth
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Quote:
Originally Posted by alpiv
Who has a wiring diagram I can look at?
Check your PM...

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Old 11-13-2008, 04:40 PM   #18
explodingmouse
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Noob Question

I have the same problem , how do you get the base cup off to get to the pigtail connections?
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Old 11-14-2008, 02:26 PM   #19
alpiv OP
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Quote:
Originally Posted by explodingmouse
I have the same problem , how do you get the base cup off to get to the pigtail connections?
Pocket knife....
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Old 11-14-2008, 02:29 PM   #20
alpiv OP
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Good News & Bad New...

Good news is the dealer found the problem(s)...

One of the original owners cut into the wiring harness near the subframe attachment, boogered it all up...

So it can be fixed (plus new stator and coils)...


BAD NEW -- wiring harness is back ordered three weeks...
and the bikes been down all summer...
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Old 11-14-2008, 02:38 PM   #21
ChrisC
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Quote:
Originally Posted by alpiv


BAD NEW -- wiring harness is back ordered three weeks...
and the bikes been down all summer...
If the harness is buggered, why not debugger it instead of replacing it?
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Old 08-02-2009, 10:41 AM   #22
RedDread
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Joined: Mar 2007
Location: Idaho
Oddometer: 32
Quote:
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?
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Old 08-02-2009, 11:46 AM   #23
gunnerbuck
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Take a Dremel and grind a slot in them for a screwdriver...
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Old 01-18-2010, 02:13 PM   #24
sac
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07 Adventure occasionally blows ignition fuse

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
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Old 01-18-2010, 02:32 PM   #25
wrk2surf
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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!
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Old 01-18-2010, 07:17 PM   #26
gunnerbuck
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Take off the right side panel and have a look at the wires going in to the relay {located at the back }... These wires have a habit of wearing through from vibration and will cause the symptoms you describe....

While your under there you might as well check the wires that run into the CDI for the same....

It's not a bad idea to go through and check the wires under the dash as well....

I do a routine wire check from front to back about every 20,000 miles and always seem to find some trouble spots that need attention...
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Old 01-18-2010, 08:37 PM   #27
sac
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Thanks,
Good to have guys willing to share from their experience.
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Old 01-18-2010, 10:04 PM   #28
bmwktmbill
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Quote:
Originally Posted by gunnerbuck
Take off the right side panel and have a look at the wires going in to the relay {located at the back }... These wires have a habit of wearing through from vibration and will cause the symptoms you describe....

While your under there you might as well check the wires that run into the CDI for the same....

It's not a bad idea to go through and check the wires under the dash as well....

I do a routine wire check from front to back about every 20,000 miles and always seem to find some trouble spots that need attention...
Sac,
This is so true, found 3-4 worn through wires this summer when my battery wouldn't stay charged. I also experienced wear on the wires emerging from the CD box.

In the case of the CD box, I filled the whole area where the wires emerge with Silicone gasket material.
That has solved the problem once and for all.
bill
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The faster it goes the faster it breaks.
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Old 01-24-2010, 04:00 PM   #29
gunnerbuck
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Well after many miles the soldered connections in my keyswitch let go again.... This time the wires that supplied the lights let go leaving me to navigate home in the dark with a handheld flashlight...

This time I ordered a new keyswitch in addition to fixing the old one again...


All cleaned up ready for soldering...


soldering complete and tested to work...


Filling the cup with silicone to insulate, support and stop the twisting action upon the soldered posts..


Cup back in place with the silicone pushing out, ready to reinstall....
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Old 01-25-2010, 02:29 AM   #30
bmwktmbill
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Buck,
That's some fancy soldering.
What's the secret??
The plastic guts are close.
Did you have a helper?

I am impressed, nice write up on what's bound to face us all.
bill
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley
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