Oil Pressure Switch

Posted: Mon Feb 08, 2010 2:09 am

Hello All,

I swapped my 06 SD for a 09 SDR a week or so ago and have been having issues with the oil light coming on at low revs (at first) and now without much in the way of a pattern. The oil level is fine and there is no leak I can find and the dealer reckons its a dodgy oil pressure switch.

I did some googling and found a thread from someone who reckons that this is a fairly common problem with SDRs and that it is caused by the connector in the oil pressure switch getting rubbed and damaged by all the hoses between the air box and cylinder heads. I had a good look this weekend and can see that the green connector on the oil pressure switch is hard up against one of the rubber hoses and so this seems plausible, but there was no wear near enough room or clearance to to the connector.

So my questions are a) has anyone heard of this being a 'common' issue with SD or SDRs and b) do I have to take the air box and throttle bodies off to get to the switch? If so how much of a drama is it to do this?

Thanks!

Posted: Mon Feb 08, 2010 9:43 pm

happened to mine after 1000km
i just took it to the dealer and told em to deal with it. i didn't listen as to what the problem was though, bla bla oil pressure sensor bla bla, that was the fourth time its been back to the workshop
my bike is nothing to go on, its actually turning out to be quite the lemon, its back in the shop again right now, bout the tenth time now all in 6 months! aarrgghh
have you had any other issues?

Posted: Tue Feb 09, 2010 12:24 am

Skasev,

What has you bike been in the shop for? What kind of problems have youbeen experiencing?

John

Posted: Tue Feb 09, 2010 12:30 am

No other issues yet, but I have only had the bike for about 1 1/2 weeks..

What other problems have you had then??

Posted: Tue Feb 09, 2010 12:53 am

water leak 4 times, replaced all pipes twice, whole coolant system in the end, all aftermarket pipes.
oil leak 3 times, 2 different places.
rear brake light not working, ziptie had cut the wire from new.
just forked out for akras and it keeps stalling when cold, i'll be riding along and it will just die, like flicking the kill switch, intermittent and with no warning, created a few hairy situations, will turn off for a few seconds then back on, then off again etc, so yesterday it died and just wouldn't start again, pushed a km to the workshop

the dealer is fantastic, i push the thing in and they work on it immediately no matter how busy they are, and they usually are. everything fixed under warranty.

Feldenak , as for your problem, like i said just go back to the dealer, let them deal with it.

Posted: Tue Feb 09, 2010 1:02 am

Thanks for that skasev... sounds like you are really going through the mill with this one! Are you enjoying though when it does work?

Yeah I will go back to the dealer and they are already aware of it. Just in normal Team Homo fashion, now I have bought the bike they show little interest so I have to keep nagging them..

I had a persistent coolant leak on my old 06 SD and it turned out to be a bad seal on the filler cap of all things.

I assume that you have had the Akra tune applied?

Posted: Tue Feb 09, 2010 2:28 am

feldenak wrote:

Hello All,

I swapped my 06 SD for a 09 SDR a week or so ago and have been having issues with the oil light coming on at low revs (at first) and now without much in the way of a pattern. The oil level is fine and there is no leak I can find and the dealer reckons its a dodgy oil pressure switch.

I did some googling and found a thread from someone who reckons that this is a fairly common problem with SDRs and that it is caused by the connector in the oil pressure switch getting rubbed and damaged by all the hoses between the air box and cylinder heads. I had a good look this weekend and can see that the green connector on the oil pressure switch is hard up against one of the rubber hoses and so this seems plausible, but there was no wear near enough room or clearance to to the connector.

So my questions are a) has anyone heard of this being a 'common' issue with SD or SDRs and b) do I have to take the air box and throttle bodies off to get to the switch? If so how much of a drama is it to do this?

Thanks!

I had the same issue with my 09 SDR on the first day. Dealer came to my house and replaced the pressure switch.
It was a 10 minute job to replace the switch.
I have put on 12000 km's since then and no problems with the oil light.

Posted: Tue Feb 09, 2010 3:00 am

Skasev,

I believe the stalling issue you are having is due to water getting in the Gray F/I connector (located behind the coolant resivoir). Pull that connector apart, dry it out and apply a liberal amount of dilectric grease to the female contacts.

A few mates and I had similar problems and that cured it completely.

Give it a try. Nothing to lose except possibly all the frustration.

John

Posted: Tue Feb 09, 2010 5:22 am

cheers John
its ready to pick up, eagerly awaiting to go get it.

Feldenak
yeah got the akra tune, wow did it wake the bike up or what!
yeah love it when its going well, i just hope all is sorted now, the dealer is pretty annoyed at all the issues but their learning from it.
i'm moving to brisbane within the next 12 months so i'll be sure to message you when i get there.

Posted: Tue Feb 09, 2010 9:51 pm

Lowrance wrote:

Skasev,

I believe the stalling issue you are having is due to water getting in the Gray F/I connector (located behind the coolant resivoir). Pull that connector apart, dry it out and apply a liberal amount of dilectric grease to the female contacts.

A few mates and I had similar problems and that cured it completely.

Give it a try. Nothing to lose except possibly all the frustration.

John

This time you beat me to it John.... Laughing

Posted: Wed Feb 10, 2010 1:35 am

Posted: Wed Feb 10, 2010 10:43 am

got mine back, was just the side stand switch, will pull that plug apart and give it some dilectric grease as instructed.
Feldenak, have you got yours fixed yet? sorry for hijaking your thread Smile

Posted: Wed Feb 10, 2010 2:51 pm

Hey skasev, glad its nothing serious and an easy fix Smile

I spoke to Team Homo and of course they won't do anything without the nod from KTM... even for a $50 part. But then I never expected much in the way of good will or decent after sales support from them!

But it sounds like it will happen eventually.

In the meantime I am enjoy the R'ness Twisted Evil

Hopefully I will have a 40T rear sprocket to fit at the weekend too!!

Posted: Thu Feb 11, 2010 4:35 pm

feldenak, just bend the sticky-out-tab 30 degrees or so, just so it doesn't touch the hose. Stick some tape on it or something.

I did it overkill:
http://picasaweb.google.com/the.joxor/SuperDukeROilLightFix#

Posted: Thu Feb 11, 2010 9:42 pm

Yeah I saw your fix Joker, its was very comprehensive. Unfortunately I am clearly not as handy as you cos I couldn't work out how to get access to it without removing the airbox and throttle bodies.

Can you tell me how you got to it?

Posted: Thu Feb 11, 2010 10:46 pm

feldenak wrote:

Yeah I saw your fix Joker, its was very comprehensive. Unfortunately I am clearly not as handy as you cos I couldn't work out how to get access to it without removing the airbox and throttle bodies.

Can you tell me how you got to it?

Thanks!

Try just sticking a long thin screwdriver in there. It's just a thin piece of metal. Bend it carefully, try to use as little pressure as possible.

Just put the screwdriver in front of the thingy and push it carefully backwards. Or perhaps try getting at it with some needlenose pliers. I didn't take anything off, but I don't have very big hands. I do remember it was veeeery tight.

Let me know how it goes.

Posted: Thu Feb 11, 2010 10:57 pm

Taking it off doesn't bother me, its just I forsee problems getting it back on! I will go and buy some new extra long needle nose pliers today and git it a go over the weekend!

Thanks Very Happy

Posted: Thu Feb 11, 2010 10:59 pm

You don't acutally need to take the wire off the connector to bend it. Smile

But needlenose pliers should probably fix it should you need to. Smile

Good luck!

Posted: Mon Feb 15, 2010 2:38 am

Cheers Joker! I got a nice long set of needle nose pliers and bent the connector down so it was no longer touching the hoses. So far so good, no oil light on this morning Smile

You da man!

Posted: Mon Feb 15, 2010 10:01 am

That's brilliant news! Sweeeeet! Cool

Having the oil light flicker is one of the worst things that can happen. Shocked

Two wheeled terror Joined: 08 Dec 2009 Posts: 149

skasev wrote:

cheers John
its ready to pick up, eagerly awaiting to go get it.

Feldenak
yeah got the akra tune, wow did it wake the bike up or what!
yeah love it when its going well, i just hope all is sorted now, the dealer is pretty annoyed at all the issues but their learning from it.
i'm moving to brisbane within the next 12 months so i'll be sure to message you when i get there.

Hi,
about the staling thing, i had a 640LC4 SM and also she did just died of sometimes, took her a few times to the dealer and it was a stupid and simple thing, the switch responsible for cutting the bike of when you put her on the side stand just was fooked, the wires go down under the seat and everytime i changed my position the wires would contact/decontact and the bike just died as if you where playing around with the engine cut off switch. Let them take a look at that.

Good luck
Luis