My KTM 690 Adventure

[Night Falcon]

Smashed my side stand switch on a rock and 950 would not start, from memory I joined the two wires together at the switch and off I went.

yeah that will work on 950 but not on 990 or 690 which has some dangfangled gizzmo that prevents it it seems ktm wants you strandard when ya sidestand switch packs up

[10bikekid]

yeah that will work on 950 but not on 990 or 690 which has some dangfangled gizzmo that prevents it it seems ktm wants you strandard when ya sidestand switch packs up

answer, buy a 950






















Just kidding of course

[vegeman]

yeah that will work on 950 but not on 990 or 690 which has some dangfangled gizzmo that prevents it it seems ktm wants you strandard when ya sidestand switch packs up

Any luck yet? My bike came with side stand switch bypass so lucky there...have you had a look through the workshop manual schematic? I'll have a look through it later.

Great news, the frame all came off yesterday.... and i did most of the wrenching.

Also, if you are not squeamish , you can watch me unscrew the first bolt out of my tibia

http://www.youtube.com/watch?v=2sfCFBjzFF4

[cynna]

im not sqeamish but that did make me sqeam

[Night Falcon]

Any luck yet? My bike came with side stand switch bypass so lucky there...have you had a look through the workshop manual schematic? I'll have a look through it later.

Great news, the frame all came off yesterday.... and i did most of the wrenching.

Also, if you are not squeamish , you can watch me unscrew the first bolt out of my tibia

http://www.youtube.com/watch?v=2sfCFBjzFF4

first things first..GREAT result on the scaffolding dismantaling, thats worth 3 bananas a major step (no pun intened) on your path to recovery!

On to lesser matters...I have run a meter over the starter switch, starter solaniod, Side stand switch and all ok. Am printing off the wiring diagram at work this arvo so will try and work through that (but I'm no electrican ). One thing I aint checked is the roll over sensor but I can imagine it would start at all if that was poked? I have a mate who is an auto electrician so may have to give him a call if I can't find the fault but want to perserver a little longer on my own to see if i can spot the problem. Weid though....no warning, starter just stopped working??

[blacksheep]

dont know if its worth checking,but see if the 2 faces on the side stand line up,i knocked mine once with the bike lift and had same problem

[Night Falcon]

dont know if its worth checking,but see if the 2 faces on the side stand line up,i knocked mine once with the bike lift and had same problem

If ithe SS switch is the problem shouldn't the bike still start in neautral? The switch is designed to turn the engine off only when its in gear with the clutch out and the sidestand down. So if its poked then the bike should start but die every time you put it in gear with the stand up or down? Plus the bike runs perfectly once ya get it going....BUT despite this lodgic I'm still leaning towards that as the problem....gut feeling....or could just be last nights fish

Can you confirm your problem did not allow the bike to start at all blacksheep?

[10bikekid]

If ithe SS switch is the problem shouldn't the bike still start in neautral? The switch is designed to turn the engine off only when its in gear with the clutch out and the sidestand down. So if its poked then the bike should start but die every time you put it in gear with the stand up or down? Plus the bike runs perfectly once ya get it going....BUT despite this lodgic I'm still leaning towards that as the problem....gut feeling....or could just be last nights fish

Can you confirm your problem did not allow the bike to start at all blacksheep?

That exactly what mine did when side stand switched went, ran fine till you tried to ride off.

[Night Falcon]

I have been scratching my nut for the past few hours checking and rechecking all the circuits connected to the starter. I'm now thinking my problem is related to the aux starter relay....which I can't find! There is definately 12v passing through the starter button when its activaed so I know thats ok.

At the other end of the circut is the starter relay which has 4 contacts on it. the top 2 both have constant 12.5volts so I have deduced they provide power to all the bikes electrics from the battery. They are also routed through the main 30amp fuse. I am therorizing the bottom 2 contacts once powered activate the starter motor and I beleive the wiring diagram confirms this. So with the key on and the starter button in there should be power to the bottom contacts to activate the starter relay....but there isn't. So somewhere between the starter button and the starter relay there is a break in the circut.

Assuming its not a broken wire (which I don't think it is) the only thing on the wiring diagram between them is the auxillary starter relay (ASR).

The ASR ties in the safety devices (roll over sensor, side stand sensor, clutch/gear sensor) to the main starter relay so that if all the correct conditions for safe starting are not met...you quessed it....the starter won't work. All I need to do is find it and check the connections on it as they are apparantly quite susceptable to corrosion. In anycase I think this is a good theory and hopefully fixes my problem. Will give it another crack tomorrow if I get a chance and report in.

Don't know if anyone is terribly interested in all this but righting it down dose help with the thinking process and maybe it will be useful to the next poor sod who finds themself stranded at the gas station

[10bikekid]

I have been scratching my nut for the past few hours checking and rechecking all the circuits connected to the starter. I'm now thinking my problem is related to the aux starter relay....which I can't find! There is definately 12v passing through the starter button when its activaed so I know thats ok.

At the other end of the circut is the starter relay which has 4 contacts on it. the top 2 both have constant 12.5volts so I have deduced they provide power to all the bikes electrics from the battery. They are also routed through the main 30amp fuse. I am therorizing the bottom 2 contacts once powered activate the starter motor and I beleive the wiring diagram confirms this. So with the key on and the starter button in there should be power to the bottom contacts to activate the starter relay....but there isn't. So somewhere between the starter button and the starter relay there is a break in the circut.

Assuming its not a broken wire (which I don't think it is) the only thing on the wiring diagram between them is the auxillary starter relay (ASR).

The ASR ties in the safety devices (roll over sensor, side stand sensor, clutch/gear sensor) to the main starter relay so that if all the correct conditions for safe starting are not met...you quessed it....the starter won't work. All I need to do is find it and check the connections on it as they are apparantly quite susceptable to corrosion. In anycase I think this is a good theory and hopefully fixes my problem. Will give it another crack tomorrow if I get a chance and report in.

Don't know if anyone is terribly interested in all this but righting it down dose help with the thinking process and maybe it will be useful to the next poor sod who finds themself stranded at the gas station

It beats fishing and watching grass grow

[dino3310]

It beats fishing and watching grass grow

BEATS FISHING!!!!!! the only thing that beats fishing is Fishing and having a beer, rod in one hand and beer in the other





as you were

[Night Falcon]

Well I found the ASR and the squished wire that was going into it so looks like I found the problem. Attached is a picture of the relay and its location for anyone who might be wondering where to find it in the future.

[dino3310]

Thats one thing i love about the XR.... no masses of wireing to worry about.
clad you found the problem, nothing worse than a electrical gremlin

[Night Falcon]

Thats one thing i love about the XR.... no masses of wireing to worry about.
clad you found the problem, nothing worse than a electrical gremlin

cheers Dino....might celebrate by going for a fish


Have also said sorry to the side stand sensor for all the rotten names I've called it over the past few days

[Waipukbiker]

Glad you found it mate, that big orange bugger was a bit heavy to pushstart, but with a team effort ( Including the cook from the P/hau pub) the beast roared into life again.