Starter relay connector problem

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Twain155
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Starter relay connector problem

Postby Twain155 » Sun Nov 30, 2014 4:35 pm

Hi Guys,

I have been having a few issues with my '09 Superduke. It's similar problems to those that have been in a few topics on here, nothing happening when turning the ignition, dash display dropping in and out as I ride, problems starting, seeing the constant errors on my dash.

So after some investigation it appears that the issue is in the connector going into the main starter relay. When turning the ignition and the bike is completely dead I can wiggle the back of the connector into the relay very lightly and very localised and it springs to life, you can hear the auxiliary relay click and the fuel pump run up and the dash kicks in.

The pics below are the connector I'm referring to, is there a way of dismantling this connector and could I buy a replacement from a KTM dealer, as you can just about see from the pic the top pins look like they have fallen apart.

Another quick question is due to this issue when I tried to start the bike one time it reset all my clocks, including the wheel diameter setting it to 5530 instead of 1870, it took me a couple of days to work out how to reset this but in that time I had to ride to work and managed to get my odometer from 15000 to 32000! obviously I didn't cover 18,000 miles in a few days, can these be set at a dealer?

Thanks!

ImageImageIMG_4053 by Mark Andrew, on Flickr

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No. 47
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Re: Starter relay connector problem

Postby No. 47 » Sun Nov 30, 2014 6:28 pm

Can't with clocks, although I guess dealer could, but spare connectors list here viewtopic.php?f=18&t=16897 and available.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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ktmguy
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Re: Starter relay connector problem

Postby ktmguy » Sun Nov 30, 2014 10:14 pm

A dealer told me once that it could be done but a wire needs to be disconnected or so to allow it to be reset.
So there night be hope.
On the other hand that dealer was pretty good and he needed to look it up, my experience with some of the "other" ones, you probably on your own!
If you don't do anything stupid when young, you have nothing to smile about when old!


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Twain155
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Re: Starter relay connector problem

Postby Twain155 » Sun Nov 30, 2014 11:04 pm

Thanks for the replies,

Have had a look and the spares manual only shows the main loom, no separate connector. Might be an eBay job!

I have spoken to my local dealer (trevor pope in Gosport) who are really helpful and they said the connector can be dismantled, but requires a specific tool, you inset into where the pins go but it goes deeper and presses a clip at the base to disengage the internals.

Having looked at the wiring diagram it all looks to make sense, pins 1 and 2 (red and white) which look like they are damaged, are hard wired to the battery positive, keeping power to the dash, and when the ignition is turned, the lights fuel pump and main power relay.
This is also the only connection between the reg/rec and the battery, meaning if this connection breaks down while riding I am not charging the battery. Again explaining why it struggles to start sometimes.

I may try hard wiring the splice to the battery to by pass this section and see if it clears the issues before I start hunting for a connector.

Regarding the odometer I have e-mailed KTM to see what their response is on having them set to the value they were before the fault.

Cheers!

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No. 47
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Re: Starter relay connector problem

Postby No. 47 » Mon Dec 01, 2014 7:23 am

Have a look at the Spare Connectors fiche, not Parts, further down the list on the sticky.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

dickiedirt
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Re: Starter relay connector problem

Postby dickiedirt » Mon Dec 01, 2014 10:02 am

I think you may be after this connector: KTM p/n 000700000AE which you should be able to buy at most KTM dealers, for example

http://www.trevorpopemotorcycles.co.uk/ ... s_id=39420

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ktmguy
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Re: Starter relay connector problem

Postby ktmguy » Mon Dec 01, 2014 10:44 am

Or try easternbeaver, he has some of the connectors.
If you don't do anything stupid when young, you have nothing to smile about when old!


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