KTM and other Euro electrical issues?

[Edbear]

Being in the battery business has been an interesting experience and I have learned a lot about bike's electrical systems and issues with different brands. While I have never had an issue with a Jappa, I do get queries about modified Harley's, Ducati's and KTM's with a customer today getting frustrated with his Husaberg.

Main issues are in too light wiring, regulators and rectifiers and most recently inconsistent decompression activation.

Apparently the ADV forums are full of discussions on these issues with the non-Jap bikes. How many get similar reliability from the Euro's as the Jappa's?

Biggest issue for me is the bikes are gradually draining the batteries either through some electrical draw with the key off or the charging system short charging the batteries which gradually flattens them.

Has anyone had and resolved these issues?

[neels]

Had a 5 year old battery die on the ducati otherwise it's been pretty trouble free, the only expensive electrical issue I've had with any of my bikes is a rec/reg cooking itself on a yamaha which also cooked the battery (mmmm, burning sulfur smell).

I suspect both the ducati and the suzuki would drain their batteries if left for too long, with a digital dash if the clock is still right when you turn it on it must be using something.

[Night Falcon]

I concur ktm wiring is not flash, too thin snaps easy. Jap reliability as far as large thumpers goes though, is a moot point since most of them have been producing the same bike for last 30 years so plenty of time to sort out the wrinkles. We need to see some new generation DR's/Klrs/XR's for real comparisons :yes: (Yammy 660 tenere is only modern japper but a bit of a fizzer really :dodge:)

[Gremlin]

Biggest issue for me is the bikes are gradually draining the batteries either through some electrical draw with the key off or the charging system short charging the batteries which gradually flattens them.

Has anyone had and resolved these issues?
Often the issues get created by poor installations, but yes, some Euro bikes have very complex systems and when left to sit for weeks, that small drain adds up.

Have had a Honda Blackbird or Hornet CB900 sit for months without attention and they start right up, it's quite disgusting. On the other hand, my 2010 GSA is coughing and complaining for a few seconds after sitting for a week or two (so hardly an old bike). Apparently the OEM batteries are known to last a couple of years, maybe 3 (sometimes the odd ones go to 5 odd years), but because the bikes are like modern cars, it's either enough voltage or not enough, no struggling. Plenty of reports of the BMW bikes suddenly not starting mid trip and needing a new battery.

Assuming installs are correct etc, and it's just the battery and/or drain, the general consensus is a new battery. I tried the Shorai as you know, which created havoc with my accessories and lights to the point I removed, installed OEM battery again, no problem. Given the bike is now 2.5 years old, I want to try another battery, but the reading up on a suitable option is gonna take a while :crazy:

[Edbear]

Often the issues get created by poor installations, but yes, some Euro bikes have very complex systems and when left to sit for weeks, that small drain adds up.

Have had a Honda Blackbird or Hornet CB900 sit for months without attention and they start right up, it's quite disgusting. On the other hand, my 2010 GSA is coughing and complaining for a few seconds after sitting for a week or two (so hardly an old bike). Apparently the OEM batteries are known to last a couple of years, maybe 3 (sometimes the odd ones go to 5 odd years), but because the bikes are like modern cars, it's either enough voltage or not enough, no struggling. Plenty of reports of the BMW bikes suddenly not starting mid trip and needing a new battery.

Assuming installs are correct etc, and it's just the battery and/or drain, the general consensus is a new battery. I tried the Shorai as you know, which created havoc with my accessories and lights to the point I removed, installed OEM battery again, no problem. Given the bike is now 2.5 years old, I want to try another battery, but the reading up on a suitable option is gonna take a while :crazy:

I have had one instance of a bike revving high after starting but he was using a smaller battery than recommended and swapping to the right battery solved the issue. Seems it is important to have the correct battery and a spot on electrical system. I'd still like to see if we can sort yours out.

[Oscar]

The main problem I've had with KTM's is their propensity to use small, expensive batteries.
I had a 625SXC and a 640E and they both ended up on battery tenders unless you used them regularly.

[warewolf]

Being in the battery business has been an interesting experience and I have learned a lot about bike's electrical systems and issues with different brands. While I have never had an issue with a Jappa, I do get queries about modified Harley's, Ducati's and KTM's with a customer today getting frustrated with his Husaberg.

Main issues are in too light wiringToo light, or not over-engineered? KTMs are built to a much tighter tolerance than the Japanese stuff. Everything does its intended job, and there's no fat. You can't just add lots of accessories to the existing wiring, it just simply not designed for it. You can happily overload the jap circuits because they carry lots of heavy extra wire ex-factory! Yet at the same time, my KTM has separate circuits for things like power sockets, navigation systems etc already fitted and ready to use.

Similar for the fasteners, typically lighter duty than jappers, do the intended job, no more. Some new KTM owners strip bolts left right and centre until they work out what a torque wrench is for, and then re-calibrate their sense of "tight".

By and large, I've had just as many issues with jap electricals as Euros, if not more.

[cooneyr]

Supposedly KTM EXC's drain battery left right and centre when not ridden for couple of weeks. I use to find I couldn't elec start mine if left for more than a month or so and would kick start first time then would start via elec afterwards. Just discovered that if I leave the choke off the till the bike fires/coughs then quickly pull out choke it starts fine even after month plus.

Maybe not so much a electrical issue but a factor of the high compression as well?

Like warewolf said - fit for purpose not agricultural engineering.

[clint640]

Yeah, KTM wiring is a bit dodgy. I'd only done 115 000km on mine before it crapped out due to wires rubbing through out of the igniter box :mad:

Worst part was I had to get towed back to town by a BMW! :weep:

One thing for a battery guy to be aware of on the KTM LC4 singles though is the auto decomp mechanism on the cam gets worn & makes the battery & starting system seem to struggle. I thought I was due for a new batt before I did my engine rebuild at 95k km but with a new cam she was turning over like new again.

Cheers
Clint

[vegeman]

I dont want to tempt fate , my 08 ktm690 has had no probs during the time I've owned it. My bike has been sitting in the garage since april, and i start the engine weekly and run it for about 10 - 15 minutes and that is all the battery gets. I put in a new motobatt AGM battery, and am impressed wuth its resliency, and cold start crank power. Always starts first push. Ive wired heated grips and installed powered accesory outlet using the 10A switched acc pre-wired cable which was very nice to see existed. All the other jappers had to have modification and relays added to get that.

[Edbear]

Yeah, KTM wiring is a bit dodgy. I'd only done 115 000km on mine before it crapped out due to wires rubbing through out of the igniter box :mad:

Worst part was I had to get towed back to town by a BMW! :weep:

One thing for a battery guy to be aware of on the KTM LC4 singles though is the auto decomp mechanism on the cam gets worn & makes the battery & starting system seem to struggle. I thought I was due for a new batt before I did my engine rebuild at 95k km but with a new cam she was turning over like new again.

Cheers
Clint

Appreciate all the responses here. I have had to learn quickly how to deal with these issues as any time someone buys a battery and has difficulties the first thing they do is contact me and say the battery is not working. I have had only a couple of cases of battery failure which is great considering the hundreds I have sold, and all the other issues arise from the bikes. The guy with the Husaberg was mentioning the decomp issue but I haven't heard of it on other bikes until now.

[rok-the-boat]

I had a Moto Guzzi 850 back in the 80s that fried all its electrics one day. It was common for MG and Dukes back then. Still happening? Crikey.

[Akzle]

I had a Moto Guzzi 850 back in the 80s that fried all its electrics one day. It was common for MG and Dukes back then. Still happening? Crikey.

was that "back in the 80s" about 4 years ago?? cos that's when this fucken thread happened.

srsly.

[pete-blen]

(Yammy 660 tenere is only modern japper but a bit of a fizzer really :dodge:)




And they have there wiring issues... light wire & the XTZs reg/rec is on the side
of the barrel... gets covered in mud/water & the plug contacts give trouble..

PS.... there are 3 versions... XTZ Tenere / XTR / XTX660 all have light wire...



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