Pop! There goes... well... everything. Shit.

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Varinn
Minimoto racer
 
Posts: 83
Joined: Mon Nov 19, 2012 4:06 am
Location: Vancouver, BC, Canada

Pop! There goes... well... everything. Shit.

Postby Varinn » Tue Aug 08, 2017 10:19 pm

Been commuting on the bike recently and had a doozie this morning. First actual failure of the KTM since I bought it 4 years back.

Had a couple stops on the way to work today and on the second one the bike cranked half a turn then made a pop noise and everything went dark. Its sitting in a parking lot of a gas station atm and I'm now at work but this is what I found. Guy at work brought me some of my tools to do a quick attempt at a diag.

Battery new at the end of last summer, strong up until now and stored on a tender through winter.
key off voltage read 11v (first sign)
key on voltage read 3v (second sign)
headlight fuse installed I get no power to anything with key on
headlight fuse removed I get enough power to fire the dash up
doesn't even consider cranking
main fuses are both ok
all little fuses were ok
jumper cables installed on positive battery post and engine case bolt the bike would crank half turn then lose power (though they had a crappy connection due to being car sized cables that barely fit on the battery)
I have no burning smells or obvious signs of serious arcing/shorts
Battery vendor tested it and said it was dead so I bought a spare

Before I install this thing and risk frying another new battery. Is it possible my starter killed the last one? How can I test it? Positive/negative posts across the starter measured 1.5ohms. How likely is it for a battery to internally fry with zero lead-up issues or warning signs?

DribbleDuke
Master of the twisties
 
Posts: 3540
Joined: Wed Nov 14, 2007 3:53 am
Location: Los Alamos, Ca

Re: Pop! There goes... well... everything. Shit.

Postby DribbleDuke » Wed Aug 09, 2017 12:38 am

check ground
I'm BLUE

Joe Biker
Stunt rider
 
Posts: 545
Joined: Wed Mar 12, 2014 1:18 am
Location: Vero Beach Florida

Re: Pop! There goes... well... everything. Shit.

Postby Joe Biker » Wed Aug 09, 2017 1:00 am

I would load test the new battery before I
Install it.
Was it just a cheap battery ?

Varinn
Minimoto racer
 
Posts: 83
Joined: Mon Nov 19, 2012 4:06 am
Location: Vancouver, BC, Canada

Re: Pop! There goes... well... everything. Shit.

Postby Varinn » Wed Aug 09, 2017 4:00 pm

It was a cheap one, bought from a battery manufacturer I deal with through work. Most of their stuff we use in our machines at work are good enough, so I figured I'd be ok for a few years but I will definitely be looking to get my money back through a warranty claim and putting it towards a Yuasa.

Checked everything before I plunked the new battery in, found no obvious signs of any issues and the major components/leads all measured out ok (no grounds unless it was one). New battery in, bike fired up immediately. Shut it down and restarted a few times for good measure and no issues so I rode it home. I'll be spending a bit more time to poke around before I ride it again though. I've never had one fail so catastrophically in such a short time and it makes me think there's more going on.

EDIT: Sidenote, when I restarted it finally I got a ton of cam chain noise but I assume all of my half-way crankovers without actually having it fire up bled the oil pressure out of the cam tensioners. Sound reasonable? They shut up after about 5 seconds but I was planning on replacing them this winter anyways as a preventative thing.

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Sarasota_Steve
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Location: Sarasota, FL, USA

Re: Pop! There goes... well... everything. Shit.

Postby Sarasota_Steve » Wed Aug 09, 2017 7:24 pm

did you get any error codes in the dashboard? Soft 101 dat 32? nothing? Typically tells you what's going on .....
Ride Hard,
------------------
Sarasota_Steve
08 990 SDR

Varinn
Minimoto racer
 
Posts: 83
Joined: Mon Nov 19, 2012 4:06 am
Location: Vancouver, BC, Canada

Re: Pop! There goes... well... everything. Shit.

Postby Varinn » Thu Aug 10, 2017 4:41 pm

It did flash the soft/dat32 codes briefly but only as the screen would die. In that sense it was the same symptoms I had when my previous battery had started to get weak in the knees and from time to time would drop voltage during cranking.

This one was different though. Ran great and powerful until this one startup where it went bang and died. After that even jumper cables seemed to be losing charge into the endless pit that was the shitty quality battery as it wouldn't start crank even with them connected. Every time it would do the "dat32" dead. Let off the starter and it would come back to life, try it again and same deal.

New battery has been great so far, only thing I haven't tested is my headlight circuit and I've still got the fuse removed there but the rest appear to have no grounding issues or shorts.


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