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Old 12-16-2007, 06:28 AM   #1
johan OP
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Electrical woes on KTM

I've got some issues with a fuse on my KTM 640Adv (the one for the dash-board and turn signals).

After changing it, it burns after 30 seconds or so. Any idea where to start looking (and for what should I be looking)? I've essentially never diagnosed electrical issues before but don't mind getting my hands dirty

/johan
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Old 12-16-2007, 06:47 AM   #2
Donkey_Kong
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Quote:
Originally Posted by johan
I've got some issues with a fuse on my KTM 640Adv (the one for the dash-board and turn signals).

After changing it, it burns after 30 seconds or so. Any idea where to start looking (and for what should I be looking)? I've essentially never diagnosed electrical issues before but don't mind getting my hands dirty

/johan
You need an ohmmeter and a test light. Unplug the wires from that fuze where they conect in the dashboard and see if they are still grounded. If they are then start looking for the ground. That's where I'd start.

If that's not the case then start looking after those connectors.
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Old 12-16-2007, 09:56 AM   #3
strongbad
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What Donkey_Kong said.

You'll need schematics and a hand full of extra fuses. Remove turn signals one-at-a-time and see if the fuse still blows. Just keep removing items from the bus protected by that fuse until the fuse stops blowing. The last item removed has the fault in it.
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Old 12-16-2007, 10:31 AM   #4
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Check the wire for you cooling fan... Mine fell on the header melted through and when the temperature gets up enough to turn the fan on it blows the fuse. Turn signals, dash lights, instruments and the fan are all on the same fuse.

As an easy fix--because removing the fan looked like a bitch--I cut the shrink wrap off of the wires just past the melted part wrapped each one in heat shrink then wrapped both of them in heat shrink and zip tied it safely out of the way...

Anyway, I'd look there first.
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Old 12-16-2007, 10:34 AM   #5
Marvin_ADV
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Sometimes wires will get pinched and cause the fuse to blow. I had the problem in the wire bundle near the steering head. Everytime I turned to the left it would blow because it was shorting out. You may want to check there.
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Old 12-17-2007, 08:29 AM   #6
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so did you figure it out?
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Old 12-17-2007, 08:43 AM   #7
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Agreed, it sounds like a grounded hot wire, either pinched or melted.
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Old 12-17-2007, 09:02 AM   #8
johan OP
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Thanks guys for all the suggestions.

Too bitchin' cold to work on this now though, must wait until I visit my father and can work in his garage
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Old 12-17-2007, 09:46 AM   #9
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Yup, pull the front fairing off and go through the loose, (unbound) wires under the dash. Sounds like something was rubbing together and probably created a short. You should be able to see/feel it.
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Old 12-17-2007, 07:03 PM   #10
jamesdemien
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Quote:
Originally Posted by johan
Too bitchin' cold to work on this now though, must wait until I visit my father and can work in his garage
If it dies when its cold out then ignore my suggestion unless you're running it on the center stand for more than 5 minutes the fan shouldn't kick on.
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Old 02-17-2008, 01:04 PM   #11
johan OP
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I forgot to close this support ticket...

Some week later when I made an effort to solve the problem, I could not reproduce the problem, the fuse did not burn any longer, and I haven't had any problems for 1000km or so.

I am just waiting for this to return though, on a larger scale, when I am out in the middle of nowhere
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Old 05-01-2008, 03:56 PM   #12
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Quote:
Originally Posted by johan
I forgot to close this support ticket...

Some week later when I made an effort to solve the problem, I could not reproduce the problem, the fuse did not burn any longer, and I haven't had any problems for 1000km or so.

I am just waiting for this to return though, on a larger scale, when I am out in the middle of nowhere
Not that this would help if you had a serious problem that kept blowing a fuse, but you can now convert your fuses to "circuit breakers" that have manual reset buttons:

http://www.snapaction.net/index.htm?include=mx5.inc


Maybe they are worth it just so you don't have to go out and buy more fuses.

Just looking for a place to put this link out there to start a discussion

I haven't found too many fuse-related woes type threads, but I only looked for a minute:

http://www.advrider.com/forums/showthread.php?t=335666
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Old 05-02-2008, 04:31 AM   #13
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Thanks for posting these MP, I might have to buy into them.
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Old 08-15-2008, 05:33 AM   #14
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All, I had the exact same problem on my 640e and now it has 'migrated' to my headlight fuse. I had the same symptoms as johan and then the mysterious disappearance as well. I'm going to check the headlight wires as well as the switch to see if I see anything.

This is most frustrating on a bike with only 1800 miles on it...

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Old 07-26-2010, 09:37 PM   #15
for-a-song
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Yup,
I just bought a 02 LC4 six days with 1700 miles on it. I haven't even been able to ride it yet and the Neutral light, Horn, and blinkers all just went out, I have only started the bike 3 times since I bought it......

I am pissed.
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