How did this happen?

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BassAgent
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How did this happen?

Postby BassAgent » Sat Jun 13, 2015 8:12 am

I'm pretty ignorant when it comes to electrical stuff. What could have caused this to happen? What are the consequences? Is something broken? Can this cause something to break? What are my options looking forward?

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Current bikes:
1990 GSXR 750 (custom streetfighter project WIP)
2006 Speed Triple 1050
2007 KTM 525 EXC (Sumo'd out)
2008 SuperDuke 990 R
2015 FZ-09
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BassAgent
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Re: How did this happen?

Postby BassAgent » Sat Jun 13, 2015 8:13 am

Btw.... I know it needs a good cleaning :oops:
Current bikes:
1990 GSXR 750 (custom streetfighter project WIP)
2006 Speed Triple 1050
2007 KTM 525 EXC (Sumo'd out)
2008 SuperDuke 990 R
2015 FZ-09
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Lowrance
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Re: How did this happen?

Postby Lowrance » Sat Jun 13, 2015 8:29 am

There is a lot of current going through that connector. Resistance has built up due to corrosion causing excessive heat which has melted the connector....that is why KTM put liberal amounts of dilectric grease in them from the factory...to prevent corrosion, but, as heat builds up, the grease gets displaced to the outside of the connector which looks like an oil leak (it isn't).

You need to replace the connector and pack it with dilectric grease.

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BassAgent
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Re: How did this happen?

Postby BassAgent » Sat Jun 13, 2015 8:42 am

Lowrance wrote:There is a lot of current going through that connector. Resistance has built up due to corrosion causing excessive heat which has melted the connector....that is why KTM put liberal amounts of dilectric grease in them from the factory...to prevent corrosion, but, as heat builds up, the grease gets displaced to the outside of the connector which looks like an oil leak (it isn't).

You need to replace the connector and pack it with dilectric grease.

It seems both ends are done for. Is the connector (m/f) sold by itself to put the wires back into? Or do I need to do some cutting and splicing?
Current bikes:
1990 GSXR 750 (custom streetfighter project WIP)
2006 Speed Triple 1050
2007 KTM 525 EXC (Sumo'd out)
2008 SuperDuke 990 R
2015 FZ-09
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No. 47
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Re: How did this happen?

Postby No. 47 » Sat Jun 13, 2015 10:37 am

Spare connectors parts fiche here viewtopic.php?f=18&t=16897
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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Aphex
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Re: How did this happen?

Postby Aphex » Sat Jun 13, 2015 6:56 pm

Was your bike dead? (dead battery). Mine died while lane splitting and I was able to bump start it while still rolling around 40mph, dash went crazy for a second then went to normal. I suspect ill find this under the chin guard.
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BassAgent
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Re: How did this happen?

Postby BassAgent » Sat Jun 13, 2015 7:07 pm

Aphex wrote:Was your bike dead? (dead battery). Mine died while lane splitting and I was able to bump start it while still rolling around 40mph, dash went crazy for a second then went to normal. I suspect ill find this under the chin guard.

Nope... Bike fires right up without any issues.
Current bikes:
1990 GSXR 750 (custom streetfighter project WIP)
2006 Speed Triple 1050
2007 KTM 525 EXC (Sumo'd out)
2008 SuperDuke 990 R
2015 FZ-09
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BassAgent
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Re: How did this happen?

Postby BassAgent » Sat Jun 13, 2015 9:58 pm

I'm looking at this page but I cant figure out which one it is?

http://www.ktm-parts.com/pdf/TechBull/S ... ectors.pdf

EDIT: Also... can I run it as is for now or is it not safe?
Current bikes:
1990 GSXR 750 (custom streetfighter project WIP)
2006 Speed Triple 1050
2007 KTM 525 EXC (Sumo'd out)
2008 SuperDuke 990 R
2015 FZ-09
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Re: How did this happen?

Postby DribbleDuke » Sun Jun 14, 2015 2:20 am

Run it, she'll be fine.
I'm BLUE

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QuietRider
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Re: How did this happen?

Postby QuietRider » Sun Jun 14, 2015 4:48 am

IMHO No rush to get the connector. You can just splice (and insulate) the wires for now and install the connector down the road when you get one.

Also those yellow wires look to be the 3 phase AC power from the stator and if so they are interchangeable as far as the rectifier/regulator is concerned so you don't really have to worry about which yellow wire goes to which regulator wire.
'08 Super Duke
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Re: How did this happen?

Postby QuietRider » Sun Jun 14, 2015 5:14 am

Also a good idea to check the stator for proper output of each phase. I had this same connector fry on my gixxer and the stator was damaged by the event. But in my case 2 of the wires were completely severed and may have shorted or who knows what??? I had to limp home 350 miles on one phase of power. Luckily I had installed a voltmeter on the bike and could see that my battery voltage would very slowly recover after a start.
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bic_bicknell
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Re: How did this happen?

Postby bic_bicknell » Sun Jun 14, 2015 6:22 am

Bass.

This is my same connector from last month that had to be replaced. I think it must have got water ingress into it because Id been doing some serious miles at fast speeds in the wet and you know how badly positioned all this stuff is behind the front wheel.

Bike was running fine though. I just couldn't leave it like that so I replaced both connectors by curing the wires and replacing the connectors. As mentioned - pack with a load of dielectric grease.
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Past: Honda CB125J, Honda TL125, 1963 Triumph Tiger 90, Yamaha RD250, Kawasaki KH250, Kawasaki 400 S3, Kawasaki KH400, Kawasaki Z400J, Suzuki GS750, Suzuki GS1000, Ducati SS900 Superlight, KTM LC4 Supermoto, Honda VFR 800i, KTM Superduke '07.

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BassAgent
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Re: How did this happen?

Postby BassAgent » Sun Jun 14, 2015 5:32 pm

Yeah I think my issue happened after some riding was done in the wet as well Bic.

QR: I think you might be onto something there. I had recently had an issue with my HID not working properly and chocked it up to a bad ballast.... but it could be that my stator went bad and was causing issues as well. I'll have to check that. Thanks.
Current bikes:
1990 GSXR 750 (custom streetfighter project WIP)
2006 Speed Triple 1050
2007 KTM 525 EXC (Sumo'd out)
2008 SuperDuke 990 R
2015 FZ-09
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SPEIRMOOR
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Re: How did this happen?

Postby SPEIRMOOR » Sun Jun 14, 2015 11:26 pm

I had same problem on my Katana. PO incorrectly using excessive amount of dilectric grease on these connectors. Dilectric grease is an insulator so if its between the terminals resistance increases . Resistance = Heat hence the meltdown. Best to add dilectric grease to the connector after connection is made to prevent and moisture from entering it.

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Re: How did this happen?

Postby fast4d » Thu Jun 25, 2015 6:35 pm

this happens to most aprilia RSV/RSVR as well. I would say it's common especially if you have multiple connectors in the chain.
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Re: How did this happen?

Postby KTMDark » Sun Jan 21, 2018 6:50 pm

Revisiting this issue. Parked my perfectly running '07SD before Christmas and plugged in the Battery Tender. Nice day yesterday, so I get it out for exercise. Hit the switch, slow to turn and SOFT indicator lights up on the dash. Pulled the cover and fuse on tender lead is blown. Look over at the R/R connector and it looks just like the one BassAgent posted. I got it all apart and cleaned up, but in my haste, didn't mark where the 3 yellow wires attached to the 3 black wires! Without a connector, how do I determine how the wires connect? The bike was running great when I parked it, with no indication of a failing R/R, but no idea how long my terminal has looked like this and if a failing R/R caused it?!? I'm not going to bother replacing the connector. I'll just reattach them, test the output, and insulate them individually once I figure out what goes where! When I test the stator wires, I've got continuity amongst all 3 leads. If this is proper, it wouldn't matter which wire went where?!? Just don't seem right?!? Any advice will be surely appreciated!
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No. 47
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Re: How did this happen?

Postby No. 47 » Sun Jan 21, 2018 8:50 pm

As above, don’t think it matters.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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Re: How did this happen?

Postby KTMDark » Sun Jan 21, 2018 9:04 pm

Kinda what I figured! I cleaned the terminals really well. Battery was 12.8V, key off, 12.5V key on. Started engine and it read 13.7v at idle, but dropped to 12.9V with revs and the 3 yellow terminals were HOT in seconds! Bad R/R?

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Re: How did this happen?

Postby No. 47 » Sun Jan 21, 2018 9:55 pm

Possibly - upgrade to Mosfet.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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Re: How did this happen?

Postby KTMDark » Mon Jan 22, 2018 3:54 am

Just ordered a Mosfet unit from Rick’s. Hopefully that will sort my boy out! Knock on wood, but this has been the only problem I’ve encountered....other than a stress cracked clock that drowned...of the myriad of issues that I’ve read about for the last 10 years! Other than a battery a couple of years back, it has never failed to start until this happened. It’s due for a front to back service, so I guess I’ll go ahead and do it while it’s down.

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Re: How did this happen?

Postby No. 47 » Mon Jan 22, 2018 8:44 am

My 996S melted the same connector without damage to reg/rec or stator - apparently common problem - replaced connector with heavy duty bullet connectors and ‘proper’ clear plastic heat shrink sheathing.

Not had same problem with either SDRs but might be good idea for you to do now if only to minimise chances of repeat issue.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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RichUK
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Re: How did this happen?

Postby RichUK » Mon Jan 22, 2018 10:22 am

SPEIRMOOR wrote:PO incorrectly using excessive amount of dilectric grease on these connectors. Dilectric grease is an insulator so if its between the terminals resistance increases .


What makes you think there was too much dielectric grease?
I think it more likely that your female connectors were weak and not making proper connection.

The clamping force that a serviceable blade connector exerts during connection is enough to literally cut a score in the mating surface, this is how they work. This force is capable of moving any amount of grease out of it's way. The rest of the space inside the connector is not taking part in the conduction of electrical current and thus may as well be filled with grease.

It might even be a good idea to seal this connector by wrapping with some self-amalgamating tape to stop any chance of water washing out the grease.


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