640 Adventure Electrical Reliability

KTMER · 01-17-2008, 05:28 AM

I’ve been trying to find info (without much luck) on the reliability of the 640 adventure CDI and other critical electrical components like the ignition coil that the bike will not run without. Some parts you can limp home without but if the CDI goes you’re done if you’re in the middle of nowhere. Even if you’re on paved roads it could be a long wait for a replacement.

Do any of you carry a spare CDI or coil, stator, or other specific electrical component. I know it’s a lot of pricey parts to carry and may never need them. How many have actually been stranded in the middle of nowhere from this type of failure? Mines an 07 btw.

Loadedagain · 01-17-2008, 06:17 AM

in my years hanging about there i don't recall hearing about any ignition failures. not to say they don't happen, but if they do nobody has mentioned it (that i've seen).

Flueger · 01-17-2008, 06:49 AM

I researched the same questions, came up with nothing. Only problem I have had electrically was the solenoid wires breaking at the solenoid plug on the bike wiring harness side. This was more just a pain in the backside as the bike would start if you kicked it.

You must be planning a run???

Flueger

Loadedagain · 01-17-2008, 07:05 AM

Quote:

Originally Posted by Flueger

I researched the same questions, came up with nothing. Only problem I have had electrically was the solenoid wires breaking at the solenoid plug on the bike wiring harness side. This was more just a pain in the backside as the bike would start if you kicked it.

You must be planning a run???

Flueger

electrical problems like you mentioned do happen from time to time. in the 25,000miles i had my 640 i had two electrical issues:

1) a wire came loose under the dash. took 30 minutes to diagnose, then fix at the road side

2) a wire broke through and grounded on my sub frame. took about two hours to diagnose and repair in a hotel parking lot as it was getting dark.

i left my cel phone charger on and it drained the battery once too... easy fix for that one though

KTMER · 01-17-2008, 07:24 AM

The occasional loose connection I'm ok with and know it will happen at some point, although still a PITA, doing electrical for a living helps with the troubleshooting. I've figured out how to bypass some of the minor switches etc that the bike will run without, I'll pack some premade jumpers just in case. Recently I found the capacitor just about falling off along with the rubber tank mount.

Re planning a run, up into Northern Ontario, maybe James Bay...

Seikkailu_R · 01-17-2008, 07:33 AM

Ignition pulser?
One possible show stopper.

Max Kool · 01-17-2008, 07:36 AM

CDI's hardly ever break. If something goes wrong eletrically, in most cases it's connectors and or chafed wiring.

Allgo · 01-17-2008, 08:23 AM

Double check your wire routing, especially after doing any work that moves things around - sub frame, accessory installs. I've had a few cases of wires rubbing through. Sometimes it takes awhile to diagnose. So I shrink tubed any wires that could potentially rub through. I carry a small spool of wire and fuses. That's about it. Oh, and of course the taillight.

KTMER · 01-17-2008, 11:21 AM

Good to hear the problems are at a minimum. Thanks for the input

dirtydeeds · 01-17-2008, 12:04 PM

I have about 50 000 km on mine, no electrical problems YET.
I have a friend with about 150 000 km on her 2000 and I don't remember hearing a story about electrical problems.

Hell though, if you have the cash and the spare room to carry that stuff, go ahead.

clintnz · 01-17-2008, 01:51 PM

45 000 km on mine & no electrical problems (apart from that damn taillight bulb holder, which is a fairly easy fix) I have noticed the odd vulnerable bit of loom here & there which I have pre-emptively wrapped up or zip tied into a better position though.

Cheers
Clint

bmwktmbill · 01-18-2008, 03:17 AM

Keep an eye on the fuse holders and give them a little squeeze to tighten the connections. My bike went dead and it was the main fuse holder. The 20 amp one near the battery. Carry twice as many fuses as you think you need, carry a spare head and tail light bulb.

Check the wires where they exit the CDI, they wear against each other. I squirted a gob of silicone glue there.

Plug and unplug everything every 10K miles. I oil my connections, others use dielectric grease. Anything to stop corossion.

Tighten the plug cap connection.

Take your wiring diagram to the copy store and have it supersized, use the best paper or map paper.

Down load and print the electrical troubleshooting section of the factory repair manual.

Buy this Radio Shack multimeter, it's a good one and will do all the tests.

http://www.radioshack.com/product/in...ductId=2104114

b.

humdinger · 01-18-2008, 04:35 AM

My '05 has proved pretty sound to date but only 11,500km.
Spade lug on one of the front brake lever popped off and shorted to ground which blew a 10amp fuse next to the battery. Took out the speedo and all lighting.
Battery terminal came loose also but I think a routine check of all electrical and mechanical fasteners (loctite the mechanical) is mandatory on these jackhammers.

KTMER · 01-18-2008, 09:42 AM

From all the replies I won't be running out to buy a bunch of pricey spare parts

. Thanks again.

RAHRAH · 01-18-2008, 11:35 AM

I did have to buy a wiring harness for my 450exc but only a fuse for the 640.

01-17-2008, 05:28 AM	#1
KTMER ^OP On roads less travelled Joined: Apr 2007 Location: Hamilton, Ontario Canada Oddometer: 295	640 Adventure Electrical Reliability I’ve been trying to find info (without much luck) on the reliability of the 640 adventure CDI and other critical electrical components like the ignition coil that the bike will not run without. Some parts you can limp home without but if the CDI goes you’re done if you’re in the middle of nowhere. Even if you’re on paved roads it could be a long wait for a replacement. Do any of you carry a spare CDI or coil, stator, or other specific electrical component. I know it’s a lot of pricey parts to carry and may never need them. How many have actually been stranded in the middle of nowhere from this type of failure? Mines an 07 btw.

01-17-2008, 06:17 AM	#2
Loadedagain making chips Joined: Jan 2003 Location: West Vancouver, BC Oddometer: 26,648	in my years hanging about there i don't recall hearing about any ignition failures. not to say they don't happen, but if they do nobody has mentioned it (that i've seen). __________________ iba - 22936 * Alcan5000 - 2006, 2008, 2012 * Stenhouse Racing - Specializing in KTM Upgrades** custom cnc service available to suit your specific needs.

01-17-2008, 06:49 AM	#3
Flueger Wandering Joined: Jun 2006 Location: Flat Land Ontario Oddometer: 115	I researched the same questions, came up with nothing. Only problem I have had electrically was the solenoid wires breaking at the solenoid plug on the bike wiring harness side. This was more just a pain in the backside as the bike would start if you kicked it. You must be planning a run??? Flueger __________________ ....

01-17-2008, 07:33 AM	#6
Seikkailu_R Studly Adventurer Joined: Jun 2007 Location: Piikkiö, Finland Oddometer: 814	Ignition pulser? One possible show stopper. __________________ -- "The concept of a versatile motorcycle equally at home on dirt and pavement is as old as motorcycling itself"

01-17-2008, 07:36 AM	#7
Max Kool Xtankteam™ Joined: Jan 2004 Location: Windmillonia Oddometer: 3,207	CDI's hardly ever break. If something goes wrong eletrically, in most cases it's connectors and or chafed wiring. __________________ Click here for an auxiliary sidetank for the BMW Xchallenge . Click here for a recalibrated speedo ring for the BMW G650X series . Max Kool screwed with this post 01-17-2008 at 07:41 AM

01-17-2008, 07:24 AM	#5
KTMER ^OP On roads less travelled Joined: Apr 2007 Location: Hamilton, Ontario Canada Oddometer: 295	The occasional loose connection I'm ok with and know it will happen at some point, although still a PITA, doing electrical for a living helps with the troubleshooting. I've figured out how to bypass some of the minor switches etc that the bike will run without, I'll pack some premade jumpers just in case. Recently I found the capacitor just about falling off along with the rubber tank mount. Re planning a run, up into Northern Ontario, maybe James Bay...

01-17-2008, 08:23 AM	#8
Allgo No Whammy,No Whammy,STOP! Joined: Jul 2007 Location: Hoeing the Hard Row Oddometer: 1,051	Double check your wire routing, especially after doing any work that moves things around - sub frame, accessory installs. I've had a few cases of wires rubbing through. Sometimes it takes awhile to diagnose. So I shrink tubed any wires that could potentially rub through. I carry a small spool of wire and fuses. That's about it. Oh, and of course the taillight.

01-17-2008, 11:21 AM	#9
KTMER ^OP On roads less travelled Joined: Apr 2007 Location: Hamilton, Ontario Canada Oddometer: 295	Good to hear the problems are at a minimum. Thanks for the input

01-17-2008, 12:04 PM	#10
dirtydeeds I'm alive. Joined: Jul 2004 Location: Red Deer, AB, Can Oddometer: 1,839	I have about 50 000 km on mine, no electrical problems YET. I have a friend with about 150 000 km on her 2000 and I don't remember hearing a story about electrical problems. Hell though, if you have the cash and the spare room to carry that stuff, go ahead.

01-17-2008, 01:51 PM	#11
clintnz Trans-Global Chook Chaser Joined: May 2004 Location: Rotoiti, New Zealand Oddometer: 2,737	45 000 km on mine & no electrical problems (apart from that damn taillight bulb holder, which is a fairly easy fix) I have noticed the odd vulnerable bit of loom here & there which I have pre-emptively wrapped up or zip tied into a better position though. Cheers Clint __________________ '03 KTM 640 LC4 Enduro The wilderness, the desert - why are they not crowded .................................................. .....with pilgrims?

01-18-2008, 03:17 AM	#12
bmwktmbill Traveler Joined: Jul 2005 Location: Traveler Oddometer: 4,070	Keep an eye on the fuse holders and give them a little squeeze to tighten the connections. My bike went dead and it was the main fuse holder. The 20 amp one near the battery. Carry twice as many fuses as you think you need, carry a spare head and tail light bulb. Check the wires where they exit the CDI, they wear against each other. I squirted a gob of silicone glue there. Plug and unplug everything every 10K miles. I oil my connections, others use dielectric grease. Anything to stop corossion. Tighten the plug cap connection. Take your wiring diagram to the copy store and have it supersized, use the best paper or map paper. Down load and print the electrical troubleshooting section of the factory repair manual. Buy this Radio Shack multimeter, it's a good one and will do all the tests. http://www.radioshack.com/product/in...ductId=2104114 b. __________________ '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 bmwktmbill screwed with this post 01-18-2008 at 03:27 AM

01-18-2008, 04:35 AM	#13
humdinger bp Joined: Feb 2006 Location: South eastern coast , Australia Oddometer: 616	My '05 has proved pretty sound to date but only 11,500km. Spade lug on one of the front brake lever popped off and shorted to ground which blew a 10amp fuse next to the battery. Took out the speedo and all lighting. Battery terminal came loose also but I think a routine check of all electrical and mechanical fasteners (loctite the mechanical) is mandatory on these jackhammers. __________________ '05 640 Adventure

01-18-2008, 09:42 AM	#14
KTMER ^OP On roads less travelled Joined: Apr 2007 Location: Hamilton, Ontario Canada Oddometer: 295	From all the replies I won't be running out to buy a bunch of pricey spare parts . Thanks again.

01-18-2008, 11:35 AM	#15
RAHRAH Adventurer Joined: May 2007 Location: Helena Ar Oddometer: 58	I did have to buy a wiring harness for my 450exc but only a fuse for the 640. __________________ Lovin it GASGAS 300 KTM 450exc KTM 640 adventure

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