KTM 640 Winter Project

[CSF]

I'm doing a HID kit and adding an extra horn and a few other accessories but thats it... still there are a bunch of connecters that don't seem to match up. I connected all of the Molex's that I could and hooked up the battery (i think its dead) and all I got from the dash was a neutral light... is it weird there there are a bunch or connecters that don't match up?
Also I went through the air box thread more then a few times... Thats where I came up with my air box mods... if you have better data on air box mods I'd be happy to use it...

[CSF]

seriously though - I really need some pics of you electrical connections...

[juames]

Originally Posted by CSF

I would really appreciate if anyone could post some detailed pics of their wire loom...? please! I have a diagram, but its of little help. Any real world photos or help would be greatly appreciated.

I have the same year as you so let me know what you need pics of and I can snap them for you no problem!

[mdlak]

Bike is looking nice CSF!

[Droptarotter]

Don't forget, there are quite a few connectors that are not used under the dash of an Adventure.

Sorry I can't help you with photo's of the electrical as my bike has been changed to the Enduro set up.

Cheers

[CSF]

Thanks! I'm pretty happy with the way its all coming along.

I'd really appreciate a few pics of the right side, around the carb and the side of the air box where the CDI is... any pics unused molex connectors would be also be appreciated too.

[bmwktmbill]

Originally Posted by Young-gun-640

Hi Bill, I'm confused now.... I may be misunderstanding what people are talking about when they say they are doing "the airbox mods"... I was under the impression that the go is not to replace the filter with a screen but rather just to replace the solid plastic side panel with a screen to allow more air into the airbox which then gets filtered by the nicely oiled air filter, am I correct?

From what you said above, it sounds like you're saying that the side panel is hollowed out as CSF has done, a screen put in the side panel as the only means of filtering the air and then no actual air-filter used to filter the air once inside the airbox... if this is the case then I'm with you, I wouldn't be doing that

Young-gun,
There is an old debate about the airbox and the BST40 diaphram carb that stems from from some dyno work done at the Sommers KTM dealership in Austria. They opened the airbox on the side an installed a rectangular screen and left the snorkel in place. They rejetted or re-needled, can't remember and got some extra horsepower on the dyno.

Someone got the idea to remove the snorkle and cut the snorkle hole bigger to accomplish the same thing. This had the advantage of keeping the ingress of water at a higher level and also dust is forced to enter at the seat level.

When more open mufflers were used some of us reasoned that more 'air' was needed from the intake end of things.

What I am saying is if you remove the snorkle and cut the hole bigger, don't block the opening with fine screen because you will restrict the flow of air into the airbox.

With the airbox closed on the sides and open on the top(enlarged hole, no snorkle, no screen) the system runs fairly clean even in heavy dust. Whe you pull the foam filter to clean it you will find dirt on the top but it will be clean on the bottom.

If you are far from home you can remove the filter and wash it clean with gas from the tank. It will dry quickly in the sun. Knock off anything loose after it dries and oil it with engine oil.

The engine will run nicely and thank you especially if you have a bunch of pavement to cover crusing back to the crib.

bill

[dnrobertson]

I have installed an 39mm FCR on my 2005 640A and also a Air Fuel Ratio meter. The bike was running rich across the board and I couldn't correct it easily, so as part of the tuning process I rode the bike without the side of the filter.

No observable difference in the AFR at all. This is with the snorkel removed and a Staintune muffler.

I also know this is controversial on this board to mention opening the airbox has no affect.

But put me on the fence regarding "opening the airbox".

David.

[CSF]

I've clipped all of my connecters back together and charged up my battery. I tested the battery and it seems to be giving me 12volts. I went over everything again and can't see that I've missed any connections other then the fuel level sensor and rear brake switch. I get nothing at the dash except a neutral light. The head lights won't fire, no horn, signals or anything that would indicate life in the system. Am I missing something? Any suggestions?

[gunnerbuck]

Originally Posted by CSF

I've clipped all of my connecters back together and charged up my battery. I tested the battery and it seems to be giving me 12volts. I went over everything again and can't see that I've missed any connections other then the fuel level sensor and rear brake switch. I get nothing at the dash except a neutral light. The head lights won't fire, no horn, signals or anything that would indicate life in the system. Am I missing something? Any suggestions?

Did you check inside the ignition keyswitch? It is not uncommon for the soldered terminals to break off inside the switches base cup causing a certain # of electrical woes...

[bmwktmbill]

Originally Posted by dnrobertson

I have installed an 39mm FCR on my 2005 640A and also a Air Fuel Ratio meter. The bike was running rich across the board and I couldn't correct it easily, so as part of the tuning process I rode the bike without the side of the filter.

No observable difference in the AFR at all. This is with the snorkel removed and a Staintune muffler.

I also know this is controversial on this board to mention opening the airbox has no affect.

But put me on the fence regarding "opening the airbox".

David.

David, it would be interesting to restrict the top of the airbox back to snorkle size to see if you get a different reading. Like you I have run my BST40 with the side panel off and it made no difference I could notice.

I had a mouse issue with my BMW airhead and 'screened' the intake openings to the airbox.

The motorcycle would not run over 70 mph.
bill

[CSF]

gunnerbuck - I googled your suggestion and found a few threads that described the symptoms that I'm experiencing. I went out this morning and took the connecter off:


2 of the wires were broken and another 2 were just about to snap off their solider points. I'm going to fix it today and fill the connecter with silicone. I'm hoping this is what causing my problems... I'm going to go over my wire loom as well and check for any worn areas.

[juames]

Woah I think I'll be checking mine.

[CSF]

Damn it. That didn't help. I still get nothing but the neutral light coming on. This is getting frustrating now...

[juames]

Originally Posted by CSF

I've clipped all of my connecters back together and charged up my battery. I tested the battery and it seems to be giving me 12volts

This might be the trouble, shouldn't the battery be reading more than 12v? Try boosting?