I have a problem that even the dealer can't seem to fix, can anyone help please?

JoJo

JoJo

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For over a month now, my SMT990 keeps cutting out. It fires up no problem, then after a mile or so, the engine dies an the FI light comes on. It doesn't seem to flash in a sequence like it's supposed to which will supposedly identify the fault according to the manual. It usually coasts to a halt but fires back up once the button is pushed. Then 500 yards later it does the same again. After a few sessions doing this, it then refuses to fire back up and on Saturday I had to abandon it in the yard of my friend's shop where I'd managed to push it to. Later I went to collect it and it fired straight up and managed to successfully ride the 1 mile back home.

The first time it happened was on a Wales ride out and whilst awaiting recovery, I rang AMS Tewkesbury to ask for advice and they advised cleaning the chain lube crud off the side stand sensor. I did this and it didn't seem to improve matters.

Sometimes after firing it back up, kicking up the stand, or knocking it in to gear, or putting some revs on will make it cut out again.

The AA collected it and delivered it to AMS KTM Tewkesbury where it was booked in for it's 19k mile service and fault diagnosis today. I have called them for an update after plugging it into their computer and doing tests on it and they themselves are scratching their heads over it, which is news i was dreading. This bike is due to sail to the USA at the end of July for the Yellowstone Tour in September so understandably, I'm worried.

Has anyone heard of anything like this happening before?
 
Have you tried by-passing the switch

KTM part that only costs £14.52 from your friendly KTM dealer!! 61011046000 DUMMY PLUG SIDESTAND

Also look at the breathers on the tanks (have thetanks been taken off for a service, perhaps) or maybe the filler caps breather, as it may be fuel starvation.
Have you cleaned the starter solinoid, not sure if your on the KTM forum, but here are a few links that I keep close to hand, just in case someone asks.
How old is it and how many miles and do you ride in the winter etc. read these if you can

http://www.ktmforum.co.uk/adventure/17747-remember-little-problem-i-had-my-990-a.html

http://www.ktmforum.co.uk/adventure/30457-electrical-woes.html

good luck
 
If it's the same as a 990 Adventure the ignition switch joins the main loom in the headstock. Check the wires from the ignition switch to the loom they can break inside the insulation, you foo meed to have a look at them as turning the bars from side to side doesn't always upset them. Second thing to check is the main ignition connector which is a white non waterproof (one of the few on the bike that isn't waterproof!?!?!?) this can be found near the star solenoid, the connections corrode which reduces the voltage and can lead to the ABS failing or ignition cut out, ABS packing in is the first sign as it's designed to fail safe so if it has anything less than full voltage it will show a fault. Third is the side stand switch which you've already mentioned. Feel free to give me a call if you want a bit more detail, I'm up until 11 this evening so feel free to call before then - 07772 144993

Let me know how you get on.

Dave
 
adventuredon said:
have you tried the katoom forum...
Click to expand...

Yes, and what a minefield of possible causes that has brought up!! If AMS Tewkesbury have to investigate all possible causes then I'll dread my labour bill


Dellis said:
If it's the same as a 990 Adventure the ignition switch joins the main loom in the headstock. Check the wires from the ignition switch to the loom they can break inside the insulation, you foo meed to have a look at them as turning the bars from side to side doesn't always upset them. Second thing to check is the main ignition connector which is a white non waterproof (one of the few on the bike that isn't waterproof!?!?!?) this can be found near the star solenoid, the connections corrode which reduces the voltage and can lead to the ABS failing or ignition cut out, ABS packing in is the first sign as it's designed to fail safe so if it has anything less than full voltage it will show a fault. Third is the side stand switch which you've already mentioned. Feel free to give me a call if you want a bit more detail, I'm up until 11 this evening so feel free to call before then - 07772 144993

Let me know how you get on.

Dave
Click to expand...

So Dave you think more electrics than fuelling?? I had a new throttle cable fitted by a local garage a few days before this problem started, they said they had a right struggle fitting it so maybe they disturbed something. As electrics are not my thing, I've forwarded your suggestions on to the garage, thanks for that, and for the offer to call you :) I'll keep you posted on it.

Allan Davies said:
Have you tried by-passing the switch

KTM part that only costs £14.52 from your friendly KTM dealer!! 61011046000 DUMMY PLUG SIDESTAND

Also look at the breathers on the tanks (have thetanks been taken off for a service, perhaps) or maybe the filler caps breather, as it may be fuel starvation.
Have you cleaned the starter solinoid, not sure if your on the KTM forum, but here are a few links that I keep close to hand, just in case someone asks.
How old is it and how many miles and do you ride in the winter etc. read these if you can

http://www.ktmforum.co.uk/adventure/17747-remember-little-problem-i-had-my-990-a.html

http://www.ktmforum.co.uk/adventure/30457-electrical-woes.html

good luck
Click to expand...

Thanks Allan, I've had a look at the links.
I've got to admit that it 'feels like a fuelling issue" Its a 2011 model, with 17k miles, I only bought it at Christmas and we haven't really had a winter as such. I took it on a trip to Ireland at the end of March and rode through torrential rain with no problems then. All has been fine until the throttle cable snapped and was replaced in the middle of April, since then this problem has emerged.

I've been given an email address for a guy who is apparently an SMT guru, in Australia, so am waiting to see what he recommends. This is the first time in my 25 years of biking that I've ever had such a hard to solve problem I'll keep you all posted, thank you for your suggestions :)
 
If they have fitted new cables, then they ought to have done a 15 minute idle to reset the ecu.
That normally cures some fuelling and rough running issues, not sure about stalling etc
15 min idle is. Cold engine ( first thing in the morning cold) start engine on the button, do not touch throttle or anything, lights, kick tyres etc lol. let it tick over for 15 mins not less.
Worth doing anyway.
Good luck
 
Other model KTM single's have had similar problems due to fuel pump issues, don't know if this is a known on your model.

Also, someone above mentioned tank breather, if the throttle cable has been replaced does that mean tank off? Probably. If so breathers are a definite possibility. Have you tried running it with the fuel cap open? Maybe even the fuel supply line kinked?
 
If they have fitted new cables, then they ought to have done a 15 minute idle to reset the ecu.
That normally cures some fuelling and rough running issues, not sure about stalling etc
15 min idle is. Cold engine ( first thing in the morning cold) start engine on the button, do not touch throttle or anything, lights, kick tyres etc lol. let it tick over for 15 mins not less.

Well I've called KTM for an update today and they agree that they've done everything that folk have suggested to me, I've got to give it to them that they do seem to know what they're doing.

Also, someone above mentioned tank breather, if the throttle cable has been replaced does that mean tank off? Probably. If so breathers are a definite possibility. Have you tried running it with the fuel cap open? Maybe even the fuel supply line kinked?

Yes that means tank off and no I hadn't tried running it with the cap open. It's being worked on as we speak so I've asked them to replace the fuel filters while it's there. Filter change isn't due this service but it will have done 25K miles by the end of the summer and it will give me peace of mind if it's done as blocked filters seems a fairly common problem. Anyway, they'll fetch the tank off again and make sure all is well afterwards.

They have told me that the fuel pipe had perished so they're replacing that, then they'll give it a road test and hopefully won't have to push it back this time. Fingers crossed that that was the culprit. I'll let you know.
 
Right guys, here's an update as promised - the bike is fixed and I've managed 200 miles over the weekend with no cutting out! However what is a little disappointing is that we are still not sure of the exact ailment which caused the problem in the first place. Here's the list of what they've done: replaced side stand sensor, fuel pump filters replaced (at my request however they weren't due until the 25k mile service), fuel pump pressure checked, re-set ECU, wiring loom checked, block connectors checked and corroded ones replaced, replaced fuel hose (as original was perished). I also had them do the 19k mile service even though it wasn't due for another 6 months as I need to have full confidence for the big trip coming up. So, thank you for taking the time to offer your suggestions. Best regards, Jo.
 
JoJo said:
Right guys, here's an update as promised - the bike is fixed and I've managed 200 miles over the weekend with no cutting out! However what is a little disappointing is that we are still not sure of the exact ailment which caused the problem in the first place. Here's the list of what they've done: replaced side stand sensor, fuel pump filters replaced (at my request however they weren't due until the 25k mile service), fuel pump pressure checked, re-set ECU, wiring loom checked, block connectors checked and corroded ones replaced, replaced fuel hose (as original was perished). I also had them do the 19k mile service even though it wasn't due for another 6 months as I need to have full confidence for the big trip coming up. So, thank you for taking the time to offer your suggestions. Best regards, Jo.
Click to expand...

Corroded connectors....... which ones, if they were the connectors I mentioned earlier then that's your problem or at least that's where my money is.

Anyway hope all goes well!

Dave
 
Dellis said:
Corroded connectors....... which ones, if they were the connectors I mentioned earlier then that's your problem or at least that's where my money is.

Anyway hope all goes well!

Dave
Click to expand...

Hi Dave,

Sadly I can't answer that as I've tried to talk to the mechanic on a few occasions, usually he won't take the call and on the last visit there in person I only managed an 'ughh' out of him, I guess his skills lie in spannering rather than in PR :rolleyes:

I presume the corroded connectors were the most exposed ones so I'm going to get it up on the ramp and go over them all with grease as recommended earlier, just to be on the safe side.

Being as though you've become my personal KTM consultant ;) can you take a look at my latest post regarding my dodgy throttle issue and see what you recommend for that too please? :D any thoughts are gratefully received
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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