Motorcycles - Page 2 - Recent Questions, Troubleshooting & Support


Hi, Brian and the usual suspects are:
1. Faulty wiring to any safety switch.
2. Safety switches loose at the mounting point.
3. Faulty kickstand safety switch.
4. Failed kickstand safety switch circuit diode.
5. Stretched side stand spring.
6. Side stand not coming up far enough to disengage switch.
7. Faulty clutch lever safety switch.
8. Faulty neutral safety switch.
9. Clutch not properly adjusted.
10. Clutch plates sticking, forward lurch
For more information about your question and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.bikechatforums.com/viewtopic.php?t=243978
https://thumpertalk.com/forums/topic/1162697-2001-ktm-640-duke-help/
https://www.tradebit.com/filedetail.php/280085454-ktm-640-duke-1998-2005-workshop-service-repair $15
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/1180172/Ktm-640-Duke-Ii.html#product-640%20Duke

2001 KTM 640... | Answered 2 days ago


Hi, Anonymous and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting/leaking, spark plug cable connections loose check for spark leakage in the dark.
6. A faulty ignition coil or electronic control module.
7. Faulty pulse coil.
8. Faulty CKP, CMP, or BAS sensor.
9. Faulty ignition switch.
10. Faulty run/off switch
11. Tilt sensor needs a reset.
12. Security alarm failing to disarm needs reset
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://ktmtalk.com/showthread.php?409216-KTM-Duke-II-LC4-No-Spark-HELP!-(please-)-(LC4-640-No-spark-Ignition-Problems)
https://advrider.com/f/threads/ktm-lc4-no-spark-help.646279/
https://www.tradebit.com/filedetail.php/280085454-ktm-640-duke-1998-2005-workshop-service-repair $15
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/1180172/Ktm-640-Duke-Ii.html#product-640%20Duke

2000 KTM 640... | Answered 2 days ago


Hi, Anonymous the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.tradebit.com/filedetail.php/280085454-ktm-640-duke-1998-2005-workshop-service-repair
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/1180172/Ktm-640-Duke-Ii.html#product-640%20Duke
https://www.motorcyclespecs.co.za/model/ktm/ktm_640_duke_ii%2002.htm
https://en.wikipedia.org/wiki/KTM_Duke_series

2001 KTM 640... | Answered 2 days ago


Hi, Anonymous the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.tradebit.com/filedetail.php/280085454-ktm-640-duke-1998-2005-workshop-service-repair $15
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/1180172/Ktm-640-Duke-Ii.html#product-640%20Duke
https://www.motorcyclespecs.co.za/model/ktm/ktm_640_duke_ii_final_edition.htm
https://en.wikipedia.org/wiki/KTM_Duke_series

KTM 640 Duke 2... | Answered 2 days ago


Hi, Anonghus569 for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $ you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzU4ODI2MS0wOC00NTA1MzBleGNyLWNhbS11cGRhdGUv
https://www.youtube.com/watch?v=vU0QPhhpJ-E
https://drive.google.com/file/d/0B2-8B_LViIendy01QklSOTRFMUk/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.ktmshop.se/documents/8403I4_OM_EN.pdf

2008 KTM 530... | Answered 2 days ago


Hi, S_s_ceramics your instrument gauges and lights can alert you to most electrical and engine issues they can not warn you about failed engine gaskets or seals so your engine has to resort to old fashion alert methods of colored "SMOKE SIGNALS" here is a breakdown of their meaning:
1. COLORLESS OR SLIGHTLY BLUE SMOKE on start-up means your air/fuel mixture is the right composition and everything is well burnt in your combustion chamber.
2. BLUE SMOKE on startup is usually caused by failed valve seals dripping oil into the combustion chamber when the engine is not running.
3. YELLOW OR BROWNISH SMOKE at start-up means your air/fuel mixture is too lean. Too lean means that there is low fuel but high air mixture in your combustion chamber.
4. WHITE SMOKE on startup may be caused by a blown head gasket allowing coolant to enter the combustion chamber and may start dripping out of the exhaust pipes or mufflers. Smoke while riding is usually caused by worn out or damaged valves, seals, guides, pistons, rings, or cylinder walls.
5. BLACK SMOKE on startup is usually caused by too much fuel in the combustion chamber this can be due to air/fuel mixture adjustment too rich, accelerator pump improperly adjusted, faulty choke or not in the off position, air filter dirty and clogged, faulty carburetor float needle and seat, pilot jet too large, fuel injectors leaking, smoke while riding is usually caused by the main jet being too large or a damaged carburetor.
It should be noted that aggressive or abnormal throttle operation will cause these conditions to manifest themselves exponentially.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the links below. Good luck and have a nice day.
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzUwNDkyNi0yMDA4LWt0bS01MzAtc21va2luZy8=
https://advrider.com/f/threads/new-530exc-smoking.594441/
https://drive.google.com/file/d/0B2-8B_LViIendy01QklSOTRFMUk/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://drive.google.com/file/d/0B2-8B_LViIenSkRkeHNINDhHdG8/view

KTM 530 EXC-R... | Answered 2 days ago


Hi, Petglo I answered this question a few hours ago, error code 1 means "no incoming signal from the ECU" my guess is you may have a faulty ground or no power getting to the ECU, check the wiring diagram in the service manual.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.manualslib.com/manual/597167/Yamaha-Majesty-400.html?page=23
https://www.motorcycle-manual.com/yamaha-fault-codes/
https://www.google.com/search?q=wiring+diagram+2009+Yamaha+Majesty+YP400G&tbm=isch&source=univ&sa=X&ved=2ahUKEwihqp3zwrLmAhUkw1kKHXXdDfMQsAR6BAgHEAE&biw=1440&bih=757
https://www.manualslib.com/manual/917861/Yamaha-2004-Yp400.html
https://www.partsfish.com/page/oem-parts-for-yamaha
https://www.manualslib.com/manual/597174/Yamaha-Majesty-400.html

Yamaha... | Answered 2 days ago


- OEM Honda Brake pads. These are the highest recommended pad on the list. They have great stopping power good feel readily available and are reasonably priced. Grade (5). - EBC Green Race. OK for a while not as good as OEM. Grade (2). - Galfer Green's,,,

2005 Hartford VR... | Answered 2 days ago


Hi, Emills7678 for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Honda, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://gl1800riders.com/forums/5-gl1800-tech-board/165547-1800-radiator-removal.html
https://www.google.com/search?q=Replace+the+radiator+2004+Honda+Goldwing+1800&source=univ&tbm=shop&tbo=u&sa=X&ved=2ahUKEwid8cnal6_mAhUuvlkKHe6SBn8Qsxh6BAgMECs&biw=1366&bih=625
https://www.manualslib.com/manual/1142922/Honda-Gl1800.html
https://www.partsfish.com/page/oem-parts-for-honda
https://www.manualslib.com/manual/805153/Honda-Goldwing-Gl1800.html

Honda... | Answered 2 days ago


Did you jump it directly from a car or did you use a booster designed for a car or truck? Some car and truck boosters can be too powerful for a bike electrical system as cars need a much higher Amp rating to turn over a bigger, heavier engine. Take it to an Auto-Electrician or bike specialist to check the other parts in the electrical system. You might have damaged either the battery or another part when you 'jumped' the bike.

Skyteam... | Answered 2 days ago


Sorry but I need more details. I can not see what you see. Please write back and tell me what you did (Step by step) to prepare the caliper for new pads. I think it would be worth double checking your work and the caliper for operation. The rear caliper is a two in one. By pressing down on the rear brake pedal. Do the rear brakes engage? When you serviced the rear brake pads. Did you remove the parking brake linkage? Actuate the parking brake lever. Do you see the parking brake linkage move? Depending on what you find. You may have to adjust the threaded rod at the caliper or you may find that something is wrong with the caliper.

Yamaha... | Answered 2 days ago


Hi, Petglo for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Yamaha, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.majestyusa.com/forums/viewtopic.php?t=6452
https://www.motorcycle-manual.com/yamaha-fault-codes/
https://www.manualslib.com/manual/752607/Yamaha-Yp400t-Yp400v-Yp400w.html
https://www.partsfish.com/page/oem-parts-for-yamaha
https://www.manualslib.com/manual/659487/Yamaha-Majesty-400.html#product-YP400T

Yamaha... | Answered 2 days ago


Hi, Anonymous and the usual suspects are:
1. Faulty kickstart gear engagement.
2. Broken kickstart return spring.
3. Bent kickstart lever.
4. Bent kickstart lever shaft.
5. Locked up transmission.
6. Locked up engine.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.ktmforums.com/threads/65sx-kick-start-gets-stuck-at-bottom-of-kick.17258/
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzExMTI3MTItaGVscC1rdG0tNjUta2lja3N0YXJ0LXN0dWNrLw==
https://drive.google.com/file/d/0B7VQ1R8fUjcieVV3eDZ5UFFRcGM/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/643632/Ktm-65-Xc-2009.html#product-2009%2065%20SX

2009 KTM 65 SX | Answered on Dec 10, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $ you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzEwMDkwMTQtc3BhcmstcGx1Zy1mb3VsaW5nLWt0bS1zeC02NS0yMDEwLw==
https://www.youtube.com/watch?v=A6PxEXGpECk
https://drive.google.com/file/d/0B7VQ1R8fUjcieVV3eDZ5UFFRcGM/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://drive.google.com/file/d/0B2-8B_LViIenZmtFRHE0dlE4eFU/view

2010 KTM 65 SX | Answered on Dec 10, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $ you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://ktmtalk.com/showthread.php?513814-2009-KTM-65-SX-fork-oil-level
https://www.youtube.com/watch?v=AMUiBdoYlxs
https://drive.google.com/file/d/0B7VQ1R8fUjcieVV3eDZ5UFFRcGM/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/643632/Ktm-65-Xc-2009.html#product-2009%2065%20SX

2009 KTM 65 SX | Answered on Dec 10, 2019


Hi, Brett the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.manualslib.com/manual/987096/Ktm-65-Sx-2009.html
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/643632/Ktm-65-Xc-2009.html#product-2009%2065%20SX
https://bikez.com/motorcycles/ktm_65_sx_2006.php
https://en.wikipedia.org/wiki/KTM_65_SX

2006 KTM 65 SX | Answered on Dec 10, 2019


Hi, Ktmrider14 for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $ you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzkzMzY4Mi13aGF0LXNpemUtc3BhcmstcGx1Zy1zb2NrZXQtZm9yLTI1MHN4Zi8=
https://www.google.com/search?q=Spark+plug+socket+size+2008+KTM+250+SX-F&source=univ&tbm=shop&tbo=u&sa=X&ved=2ahUKEwja_J3Z3KnmAhVMjlkKHSWwAaUQsxh6BAgLECg&biw=1440&bih=757
https://drive.google.com/file/d/0B2-8B_LViIenQ0x1eV9ILUpKYlU/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://drive.google.com/file/d/0B2-8B_LViIeneEtSYnlCLWplX3c/view

2008 KTM 250... | Answered on Dec 10, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $ you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.manualslib.com/manual/584679/Ktm-65-Sx.html?page=80
https://www.youtube.com/watch?v=AMUiBdoYlxs
https://drive.google.com/file/d/0B7VQ1R8fUjcieVV3eDZ5UFFRcGM/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/643632/Ktm-65-Xc-2009.html#product-2009%2065%20SX

2009 KTM 65 SX | Answered on Dec 10, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $ you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzExMDc1ODctc3BhcmstcGx1Z3MtZ2FwLw==
https://www.ktmshop.se/documents/6001E6_TDE_EN.pdf
https://www.manualslib.com/manual/987096/Ktm-65-Sx-2009.html
https://www.partsfish.com/page/oem-parts-for-ktm
https://www.manualslib.com/manual/1150171/Ktm-65-Sx.html

2009 KTM 65 SX | Answered on Dec 10, 2019


Hi, Anonymous and the usual suspects are:
Leaks are the most common sign of water pump failure, but what type of seepage are you seeing and what does it mean?
A coolant leak coming from the weep hole is a sign of water pump bearing or seal failure. This weep hole often resides between seals that separate the oil side from the coolant side. A small amount of "dry" seepage around the hole can be considered normal, but it's only a matter of time before a seal becomes defective and the seep turns into a drip. A coolant leak into the front cover area, connected to the oil sump, means the outer O-ring has failed. This could mimic a head gasket leak.
Adding cold coolant to an overheated engine can cause thermal shock and create a seal leak even in a new water pump. Starting an engine during a water pump replacement before adding coolant could have the same effect. Look for a crack across either the seal face or the mating ring as evidence.
Allow an overheated engine to sit and cool before adding coolant. Then, restart the engine and allow it to run while slowly adding the remainder.
Abrasive particles accelerate water pump seal wear. For example, systems that are not properly pressurized allow air to enter and foster the build-up of rust. Or, if water with a high mineral content is added to the system and is heated, it will begin to form deposits that will accumulate and cause passage restrictions. Both of these are harmful to seals.
Although rust is difficult to remove, it should be flushed from the system as thoroughly as possible before the old water pump is removed.
When replacing the pump, O-rings need to be lubricated with either oil or coolant. Do not use silicone or other sealants that can block the weep hole.
Cavitation is the formation of vapor cavities in a liquid as a result of forces acting upon the liquid, like rapid changes of pressure. Cavities form when pressure is relatively low, and then when subjected to higher pressure, the voids implode and can generate an intense shockwave. What's this mean for a water pump?
Water pump efficiency can depend greatly on the impeller and housing design. If there is excessive turbulence as a water pump impeller circulates through coolant, cavitation can occur, which hurts pumping efficiency and can cause further erosion of the impeller and impeller housing.
Water pumps serve as an idler pulley on many engines equipped with timing belts and, due to accessibility issues on many transverse engines and the labor operations involved in replacing the timing belt (especially on imports), it's cost-effective to invest in a new water pump as well, especially if the pump is near the 100,000- to 150,000-mile recommended replacement mark.
Water pumps can sometimes support a mechanical fan. If the fan assembly falters in some way, like from a bent fan blade or a severely cracked assembly, bearings can be affected. For evidence, look for casting breakage around the bearing support as this is typically caused by excessive vibration or an imbalance caused by a badly worn fan or clutch. To remedy, inspect the pulley, belt alignment and fan/fan clutch assembly, replacing any bent or worn components.
Blue discoloration of the water pump shaft would indicate excessive heat buildup for some period, eventually ending in breakage of the shaft. This heat buildup can be caused by the tremendous centrifugal forces created by imbalance, which overloads the bearing and generates a ton of heat. A clean break indicates an "instantaneous" fracture caused by sudden overload or imbalance at the bearing.
To remedy, check the pulleys for proper alignment, straightness and fatigue. Inspect fan/fan clutch assembly for a bent or damaged fan, a worn spacer, or a worn or damaged fan clutch.
Noisy shaft bearings are the second-most common reason for water pump failure. Most shaft bearings fail due to normal wear in the bearing or due to the normal oxidation of lubricant on the bearing surfaces. In rare cases, bearing failure can be hastened by over-tightening conventional accessory drive belts.
The less common water pump failure is the impeller slipping on the water pump shaft. A good water pump impeller will cause the pressure to increase as the engine is accelerated. If pressure does not increase, the impeller is slipping on the shaft or is missing impeller blades. In general, a good water pump should develop at least 10 psi of pressure above 2,000 rpm.
Since the impeller and shaft are a press-fit assembly, slippage occurs most frequently on remanufactured water pumps. In any case, ­slippage can be intermittent in nature and can depend greatly upon the temperature and speed of the engine.
Some replacement impellers can be manufactured from inferior metals that are susceptible to rust corrosion. In most of these cases, impeller blades begin to break away from the impeller due to a rust-through condition, which results in decreasing pumping capacity and an increasing presence of rust contamination in the cooling system.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://thumpertalk.com/utilities/support-those-that-support-you/?ref=aHR0cHM6Ly90aHVtcGVydGFsay5jb20vZm9ydW1zL3RvcGljLzU4Mzg4My13YXRlci1wdW1wLXdlZXAtaG9sZS1sZWFrLw==
https://advrider.com/f/threads/08-11-ktm-450-530-water-pump-seal-replacement-how-to.769378/
https://drive.google.com/file/d/0B7VQ1R8fUjcidWsyTzVlMFMxTDQ/view
https://www.partsfish.com/page/oem-parts-for-ktm
https://drive.google.com/file/d/0B2-8B_LViIendy01QklSOTRFMUk/view

2008 KTM 450... | Answered on Dec 10, 2019

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