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Old 03-09-2014, 08:11 AM   #61
Tomah
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Thank you NeptuneTriton

Checked my '11 990-R last night and saw the same thing happening. Luckily the wires are still OK. Given the kink that had formed, it was just a matter of time until I ended up stranded on some dark and stormy night.

I cut out a channel for the wires, smoothed off the rough edges, and now the harness can move as it should.

Thanks NT!
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Old 03-09-2014, 02:05 PM   #62
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Checked mine this morning and it's the same as the rest of you guys. Why aren't you just removing the plastic covers instead of taking the time to trim? It looks to me that there just filler pieces.
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Old 03-09-2014, 02:38 PM   #63
armourbl
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Quote:
Originally Posted by Ladukebob View Post
Checked mine this morning and it's the same as the rest of you guys. Why aren't you just removing the plastic covers instead of taking the time to trim? It looks to me that there just filler pieces.
There are a mess of wires all jumbled in that space. To do it right I think you'd have to zip-tie them up in some managed fashion.

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Old 03-09-2014, 03:25 PM   #64
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I did think about removing them, as they really seemed cosmetic. But I figured they may stop some dirt / water / crap covering the wires underneath.

Plus the sun was out, I had time to kill and trimming a bit off was really only a five min job.
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Old 03-09-2014, 04:39 PM   #65
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did mine earlier, brand new old stock and only done 100 miles but see the kink line where the cable is bending because there's no freeplay in the cables.
I trimmed the plastic giving it a rounded end and removed the hook kinda thingy on the inside. Main cable has easy movement now when you turn the bars, thanks for the heads up.

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Old 03-09-2014, 04:58 PM   #66
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Radius on the plastic thingy, I noticed that some are saying they just cut it, does that not leave a sharp edge on the plastic ?


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Old 03-09-2014, 07:55 PM   #67
tacosupreme
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Quote:
Originally Posted by Ladukebob View Post
It looks to me that there just filler pieces.
I think they are there to keep thieves from pawing at the factory option alarm... The plastic covers showed up at the same time the alarm option did.
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Old 03-20-2014, 09:17 PM   #68
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is the trimming effective?

Just wondering if trimming the plastic is effevtive, or is the wiring harness too short?
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Old 03-20-2014, 11:25 PM   #69
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Under 1500 miles. Already wearing through the outer protective wire casing. Used a wire cutter to get in and take off the offending corner, which BTW had a sharp edge on the back.



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Old 03-21-2014, 08:14 AM   #70
BT4Stroke
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You all need to go inside and undo the zip tie that is holding them in place and allow for more slack in the wiring so it's not so tight. Trim the panel back so that they float freely between the frame at the bend. This will eliminate any binding.
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Old 03-21-2014, 11:17 AM   #71
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This has also happend to me

Went through this as well. Wires are much too brittle. Repaired it with aircraft grade teflon wire.

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Old 03-21-2014, 11:29 AM   #72
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Trimmed the cover on my 2007 990 with 45,000 miles.
I didn't see and cutting or negative results on the wire from the last 7 years but trimmed it to be safe.
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Old 03-21-2014, 11:29 AM   #73
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'08 with 20,000 on the clock and no damage showing.



Snipped the cable tie and took a dremel to the cover to be sure. I almost removed the covers altogether, but I figured they must help keep out a lot of crap.



I noticed the cables slid in and out when I turned lock to lock so I gave it a protective wrap of insulation tape to be sure.

Thanks for the heads up, this surely is an oversight in the design.
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Old 03-21-2014, 12:35 PM   #74
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This has most likely already been said, but I would recommend that ALL 990 owners fix this even if it hasn't become a problem yet. It will become a problem at the worst time and you don't want to be "That Guy" in a group.
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Old 03-21-2014, 03:00 PM   #75
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Well, the dealer called yesterday and said they had received the part from KTM. They scheduled me in this morning and got it swapped out. They said that when they contacted KTM for the Warranty, KTM didn't even attempt to dispute it or ask for any documentation - they said to just swap it out.

Sounds to me like between the back-order on the part and the green light to just fix it under warranty, KTM has probably had to deal with plenty of these ignition harness failures. Anyway, problem solved! Props to KTM and my dealer for taking care of it so fast and I'm glad this thread has helped keep other riders from getting stranded!
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