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Old 01-25-2010, 03:23 AM   #31
clarky
05' 640 Adv
 
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Joined: May 2007
Location: Lost
Oddometer: 460
While we are on all things weird and wonderful in KTM's electrics, can anyone direct me to the thread that I remember seeing donkeys years ago about what is going wrong when your headlights begin flashing from one to the other.

It is on an 05 640 Adventure, with xenonrider.com HID kits High & Low, with the high/low mod done.

cheers

Clarky
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Old 01-25-2010, 10:06 AM   #32
gunnerbuck
Island Hopper
 
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Joined: Nov 2005
Location: N.V.I, B.C.
Oddometer: 3,819
Quote:
Originally Posted by bmwktmbill
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
I thought it was pretty messy....

The first thing I did to prep the posts was to heat the broken off ends and pull them out of the solder. This freed up the wire receiver cups for the new wire....


To keep from melting the plastic I heated the wire and not the base blob... When the wire was hot enough it would melt the solder as I pushed it in....
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Old 09-03-2010, 07:37 AM   #33
IamTRooPeR
TRooPER from Belgium
 
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Joined: Jan 2008
Location: East Flanders' Ardennes Belgium
Oddometer: 131
I seem to have an electrical problem,

It happens the last week several times, but very unregular.

problem is that the fuse of the horn-blinkers-display-brakelight is blown

first time was after shutting down the engine with the kill switch,
second time when I hit the start button
last time - just on the road while riding and not pushin any button:
Flop - fuse blown and no display anymore.

anyone with a suggestion to sort out any problem?
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Old 09-06-2010, 12:05 AM   #34
bmwktmbill
Traveler
 
Joined: Jul 2005
Location: Traveler
Oddometer: 4,791
Better take off the seat and have a look at the wiring for the tail light and the blinkers.

The wiring diagram will help with colors.
Look for wires with worn insulation.
bill
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The faster it goes the faster it breaks.
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Old 01-09-2011, 11:00 AM   #35
Low594
Adventuring Creep
 
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Joined: Oct 2008
Location: Oakland, CA
Oddometer: 1,127
Thanks to gunnerbuck!
I will be checking out a few leads from this thread and another.

Issues:
-tach & taillight not lighting; jiggle the key and its fixed for a few hours or a day
-headlight not lighting; moved wires under dash and it was fixed, but then:
-engine shut off; no restart, only a click at the starter
-tach needle bounce; since i bought it early last year; maybe related? Maybe not?!
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Old 06-23-2011, 11:33 PM   #36
yvautrin
Dive & Ride
 
Joined: Sep 2010
Location: Sharm El Sheikh, Egypt
Oddometer: 21
electric starter problem

Hi to all!

after my trip around Egypt on the 990 Adv S '08 (thanks to your help on some technical issues and for following us on or website!), my back tyre being absolutely worn, and the new one arriving in 3 weeks, I decided to give some rest to the 990 and ride my 640 LC4 '00 for a while.

As I did not use it for a while, I started by charging fully the battery.

Now, with battery fully charged, everything is working fine (horn, light, etc...) but the bike won'y start... I checked the fuses, they are ok, when I press the "stop" button on the starter, I can hear the relay working, but the bike won't start by kick, and when I press the electric start button, nothing happens at all...

Two things I noticed which my be the source of the problem :

1. the choke cable is broken (is there a safety feature on the bike to prevent it to start with broken choke cable?) if then, what to do? disconnect it? replace it?

2. opening the headlight support in the frnot, there is a black & yellow electirc cable connected to nothing? (where should it go? what is the purpose of this cable?)

Thanks for your help!

Yann
www.divingbikers.net
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Old 07-31-2012, 04:10 AM   #37
warewolf
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Joined: Oct 2004
Location: Nelson, New Zealand
Oddometer: 2,357
Just discovered and fixed this problem, too; thanks for the thread.

It's something I've been meaning to look at for a while, since my bike now has 50,000 km on it. The other day when I parked the bike, light switch on but ignition switch off, turning the bars would make the headlights turn on. The time to take a look was now...

Red-white was completely snapped, as was blue. Green-black had a hole worn in the insulation from rubbing against another wire. Green had half the strands attached, but was badly frayed with insulation missing, so must have been shorting against the other broken stumps of wire. :eek:

On my 2005 EU/AU Adventure, the pigtail was only about 200 mm long (maybe less), and I cut 20 mm off it to re-terminate the wires. It is now almost but not quite tight/straight when the bars are turned full left, necessary to lock the steering, so this trick cannot be done again without adding wire back.
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Colin
KTM LC4 640 Question? Check here first --> KTM LC4 (640) Index Thread
Quote:
Originally Posted by Steve McQueen
All racers I know aren't in it for the money. They race because it's something inside of them... They're not courting death. They're courting being alive.
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Old 07-31-2012, 06:08 AM   #38
meat popsicle
Ignostic
 
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Joined: Feb 2004
Location: Circumlocution Office of Little Dorrit
Oddometer: 14,147
Quote:
Originally Posted by warewolf View Post
Just discovered and fixed this problem, too; thanks for the thread.

It's something I've been meaning to look at for a while, since my bike now has 50,000 km on it. The other day when I parked the bike, light switch on but ignition switch off, turning the bars would make the headlights turn on. The time to take a look was now...

Red-white was completely snapped, as was blue. Green-black had a hole worn in the insulation from rubbing against another wire. Green had half the strands attached, but was badly frayed with insulation missing, so must have been shorting against the other broken stumps of wire. :eek:

On my 2005 EU/AU Adventure, the pigtail was only about 200 mm long (maybe less), and I cut 20 mm off it to re-terminate the wires. It is now almost but not quite tight/straight when the bars are turned full left, necessary to lock the steering, so this trick cannot be done again without adding wire back.
Oi Colin,

I'm only above 30,000 km so maybe I have some time before my wiring starts to wear out (sound like old men... :). I also have rewired my headlights with an Eastern Beaver kit in order to improve the voltage supplied to the headlights so I might have a bit more than that too. Jim makes nice kits and has great customer service.

Don't forget to aim your headlights too
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Old 08-01-2012, 01:40 AM   #39
warewolf
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Joined: Oct 2004
Location: Nelson, New Zealand
Oddometer: 2,357
Ta for that, I'll comment in the other thread
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Cheers,
Colin
KTM LC4 640 Question? Check here first --> KTM LC4 (640) Index Thread
Quote:
Originally Posted by Steve McQueen
All racers I know aren't in it for the money. They race because it's something inside of them... They're not courting death. They're courting being alive.
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