Electrical woes on KTM

johan · 12-16-2007, 06:28 AM

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

Donkey_Kong · 12-16-2007, 06:47 AM

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.

strongbad · 12-16-2007, 09:56 AM

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.

jamesdemien · 12-16-2007, 10:31 AM

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.

Marvin_ADV · 12-16-2007, 10:34 AM

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.

jamesdemien · 12-17-2007, 08:29 AM

so did you figure it out?

Kawidad · 12-17-2007, 08:43 AM

Agreed, it sounds like a grounded hot wire, either pinched or melted.

johan · 12-17-2007, 09:02 AM

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

12-17-2007, 09:46 AM

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.

jamesdemien · 12-17-2007, 07:03 PM

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.

johan · 02-17-2008, 01:04 PM

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

meat popsicle · 05-01-2008, 03:56 PM

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

Wylie · 05-02-2008, 04:31 AM

Thanks for posting these MP, I might have to buy into them.

jachard · 08-15-2008, 05:33 AM

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...

James

for-a-song · 07-26-2010, 09:37 PM

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.

12-16-2007, 06:28 AM	#1
johan ^OP Gnarly Adventurer Joined: Jul 2005 Location: Mjölby, Sweden Oddometer: 249	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

12-16-2007, 10:31 AM	#4
jamesdemien Studly Adventurer Joined: Sep 2007 Location: St. Louis Oddometer: 551	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. __________________ If you don't fall you're not going fast enough? Gateway BMW Motorcycles St. Louis \| Digital Marketing Strategy \| Alaska Trip Wishlist \| SPOT \| Vimeo

12-17-2007, 08:29 AM	#6
jamesdemien Studly Adventurer Joined: Sep 2007 Location: St. Louis Oddometer: 551	so did you figure it out? __________________ If you don't fall you're not going fast enough? Gateway BMW Motorcycles St. Louis \| Digital Marketing Strategy \| Alaska Trip Wishlist \| SPOT \| Vimeo

12-17-2007, 08:43 AM	#7
Kawidad Beastly Adventurer Joined: Jul 2005 Location: Central Coast, Cal Oddometer: 3,808	Agreed, it sounds like a grounded hot wire, either pinched or melted. __________________ "Deeply flawed people make deeply flawed decisions."

05-02-2008, 04:31 AM	#13
Wylie Back in the saddle again Joined: Jul 2007 Location: Shoshone, Idaho Oddometer: 2,232	Thanks for posting these MP, I might have to buy into them. __________________ Okay so I'm not Super Man. I'm just the jack of many trades, master of some yet to find and as the world turns that would only be for a matter of time. Okay, screw it, stop the world I'm getting off.

12-16-2007, 09:56 AM	#3
strongbad Gnarly Adventurer Joined: Jun 2006 Location: Arroyo Grande, CA Oddometer: 428	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.

12-16-2007, 10:34 AM	#5
Marvin_ADV Gnarly Adventurer Joined: Apr 2007 Location: Norfolk, VA Oddometer: 432	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.

12-17-2007, 09:02 AM	#8
johan ^OP Gnarly Adventurer Joined: Jul 2005 Location: Mjölby, Sweden Oddometer: 249	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

12-17-2007, 09:46 AM	#9
SFmax Guest Oddometer: n/a	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.

02-17-2008, 01:04 PM	#11
johan ^OP Gnarly Adventurer Joined: Jul 2005 Location: Mjölby, Sweden Oddometer: 249	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

08-15-2008, 05:33 AM	#14
jachard Gnarly Adventurer Joined: May 2008 Location: NYC, CT Oddometer: 394	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... James __________________ 2005 640e 2012 R1200GS Rallye 1993 Porsche 964 RS www.racersandranchers.com

07-26-2010, 09:37 PM	#15
for-a-song adventure Joined: Mar 2008 Location: Bellingham, WA Oddometer: 44	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. __________________ 02 KTM LC4 Six Days...GO GREEN!!!

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