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Old 03-29-2013, 10:42 AM   #1
Eats Dirt OP
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Joined: Jun 2008
Location: Lincoln, NE
Oddometer: 32
2001 KTM 640 LC4 electrical problem

My bike dies as soon as I put it into gear.
1.) It starts and runs fine in neutral. The neutral light works.
2.) Thinking that it's the clutch switch, I took the switch out of the circuit using a jumper wire across the plug behind the headlight mask, no change.
3.) I found a pinched wire under the seat and dressed that up, no change. The pinched wire looks like it goes to a diode. I'm out to test that next, just because.
4. I think that what ever failed did it over a course of about 5 blocks, simulating fuel starvation (out of gas). I was low on gas but at the filling station the hard "dies going into gear" problem became evident.
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Old 03-29-2013, 10:49 AM   #2
motomal
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Joined: Oct 2008
Location: Devon, U.K.
Oddometer: 163
I had a 2000 LC4 400 which did this to me out on a trail ride once. The side stand switch had been bypassed and removed with the left over wiring still under the seat near the battery. A bullet connector had come free so the bike always thought the side stand was down. Plugged it back in tight and no further problems.

I don't have the bike any more to see what colours the wires are etc but if you can't trace them I'm sure someone will come along with the necessary info.

Good luck.
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Old 03-29-2013, 11:17 AM   #3
Seikkailu_R
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Joined: Jun 2007
Location: Piikkiö, Finland
Oddometer: 828
Isnt clutch switch more connectet to starting bike with gear on?
you can normally use clutch with bike running, no matter if gear is on neutral or not.

But sidestand switch is different thing, it kills engine if not on neutral.

Time to check wiring loom...
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Old 03-29-2013, 11:25 AM   #4
Eats Dirt OP
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Joined: Jun 2008
Location: Lincoln, NE
Oddometer: 32
Yup, side stand switch. I had just found in the manual that I had one when I read your response. The problem has now been permanently eliminated as it's certainly nothing this dirt bike needs!

Thanks for the quick response.
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