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Old 03-02-2014, 06:15 PM   #31
NeptuneTriton OP
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Trim Black Plastic Igntion Wire Bundle

So, here's what I did that fixed the pinching problem. I didn't want to get rid of the black plastic cover completely, so I just trimmed the corner off of it where it pinches the wire bundle against the frame:

 photo 55bbb9c7-9eee-44ad-aa6e-d1085a01b497_zpsd4f71ea0.jpg
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Old 03-03-2014, 07:08 PM   #32
Vector Leto
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Photos and a video of my bike

2012 990 R

Wire bundle between the plastic and frame.



Wire bundle headed up toward the triple clamp, then back down left to right.

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Vector Leto screwed with this post 03-06-2014 at 06:32 AM
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Old 03-03-2014, 07:37 PM   #33
Dusty
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Quote:
Originally Posted by NeptuneTriton View Post
So, here's what I did that fixed the pinching problem. I didn't want to get rid of the black plastic cover completely, so I just trimmed the corner off of it where it pinches the wire bundle against the frame:

Why not? You'll get better cooler air flow to the air box... I ditched mine the first winter maintenance that i got my bike.

Good post for bringing this forward.
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Old 03-03-2014, 08:48 PM   #34
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Originally Posted by Dusty View Post
Why not? You'll get better cooler air flow to the air box... I ditched mine the first winter maintenance that i got my bike.

Good post for bringing this forward.
Older 990 and 950 don't have that plastic part. I am guessing KTM added that for the showroom!
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Old 03-04-2014, 11:10 AM   #35
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Thanks for the thread. I emailed the link to it to my dealership that still has my 990 SMT. They're calling KTM USA today about it. Hopefully they'll cover the cost of the repair, I'm 3 weeks out of warranty- it's obviously a defect.
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Old 03-04-2014, 11:46 AM   #36
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So, the nearest KTM dealer called today to tell me that he put the new ignition harness on order and guess what? They're back ordered until the end of April. I think that further validates that this is a widespread issue since they are all out of ignition harnesses.

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Old 03-05-2014, 11:50 AM   #37
chill622
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Bummer, will have to look into this. No indications after 7000 miles. Has anyone found this to NOT be an issue? Meaning, did KTM eventually re-route or make a change on later models? Are dealers addressing this under warranty?
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Old 03-05-2014, 12:39 PM   #38
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More reports from across the pond...

Someone on the LC8 Facebook Page directed me to the forums in Europe where several other riders are experiencing the same issue...pictures and details here:

http://forum.lc8.info/viewtopic.php?...lo%DF&start=30

http://www.ktm950.info/how/ktm_950_issues.html
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Old 03-05-2014, 12:40 PM   #39
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Bummer, will have to look into this. No indications after 7000 miles. Has anyone found this to NOT be an issue? Meaning, did KTM eventually re-route or make a change on later models? Are dealers addressing this under warranty?
Well, the Baja is the latest model. In fact, I think the earlier models did not have this design. Go figure.
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Old 03-05-2014, 12:44 PM   #40
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And yet more from the UK reporting on it...

http://www.ktmforum.co.uk/adventure/...g-harness.html
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Old 03-05-2014, 12:47 PM   #41
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Well, the Baja is the latest model. In fact, I think the earlier models did not have this design. Go figure.
It looks like any of the 990's with the cosmetic black cover in the frame are affected, not just the Baja's. My understanding is that the earlier 950's and 990's didn't have these covers, so they've been problem free. I just want people to catch the problem before they get stranded on a remote trail or pull out into traffic and have their bike suddenly die on them.
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Old 03-05-2014, 01:20 PM   #42
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Dealer called me. They read this thread and checked my bike. My wires are fine but ignition switch is bad. Will take 3 weeks to get one programmed and keyed by ktm. Not under warranty either.
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Old 03-05-2014, 02:12 PM   #43
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my 2011 is in storage at the moment and I am away from home, could anyone with a 2011 tell me whether that year has the suspect black plastic cover ? if it does i want to get back and check it before my warranty runs out. (it was a remaindered 2011 registered in 2012).

thanks

tim
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Old 03-05-2014, 03:11 PM   #44
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Originally Posted by zeropoint View Post
my 2011 is in storage at the moment and I am away from home, could anyone with a 2011 tell me whether that year has the suspect black plastic cover ? if it does i want to get back and check it before my warranty runs out. (it was a remaindered 2011 registered in 2012).

thanks

tim
My 2011 990R had it.

/Johan
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Old 03-05-2014, 05:01 PM   #45
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Ive seen them on several 2007s on this site. Same as mine, when i removed mine i did a tidy up of the whole wire situation up front, around the headlight also. The pictures of the 950s looked like the cable routing was much nicer, thats why i reworked mine.

Now ya all need to put a rating on this thread so it doesn't get buried like most of the good ones.
I sure wish people would have done that for the chain slider that was flying off locking up the rear wheel and almost killing people.

Give it a 5 star so it can be sorted with the other 5 star threads.
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