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690 cutting out when taken out of neutral ? 690 cutting out when taken out of neutral ?
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  #1  
Old 19 Aug 2014
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690 cutting out when taken out of neutral ?
Hi i recently brought a 2012 690 Enduro R

I gave it a good clean then a going over with ACF 50. I also disconnected and removed the battery to wipe any gunk away and installed a Garmin Montana power mount.

When i put everything back together the bike started fine but keeps cutting out every time i try to take it out of neutral.
I have tried taking it into first and second both on the move and static but it just cuts out as soon as i touch the gear selector pedal.

Is there a reset to be done after you disconnect the battery perhaps ?

has anyone had the same or similar happen to them ?

Any help gratefully received.

No Fromage

:confused1:
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  #2  
Old 19 Aug 2014
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Probaby sidestandswitch/magnet.
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  #3  
Old 20 Aug 2014
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I'd also guess side-stand switch, or failing that, clutch switch (if the 690 has such a thing).
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  #4  
Old 20 Aug 2014
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As others say it's most likely the side stand safety switch. Check the connection to the switch and give it a good squirt of WD40. Also check you havent snagged the wire during cleaning... A lot of people remove the switch completely



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Bones
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  #5  
Old 20 Aug 2014
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Just had a look online and looks like this is a common problem. It you want to remove it for good Rally raid do a plug in by pass dummy switch for £23.. See attched link

Side Stand Dummy Plug



Bones
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  #6  
Old 21 Aug 2014
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I'm not sure if the 690 has clutch or sidestand switch or both but you need to get rid.

My mate's 690 is a right-royal PIA because you can't start it in gear. I disabled both the sidestand and clutch switch on my DRZ within a day of buying it. So far I have managed not to ride off with the stand down or try and start it without the clutch in. I have always pulled the clutch in when starting anyway.
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  #7  
Old 21 Aug 2014
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Agree
Roger last message !

It is going to KTM on tuesday for diagnostics but i have ordered a bypass switch in any case.

Thing is it was fine until i disconnected the battery i just can't work out what difference that made ?

I will post the outcome when the issue is resolved.

Regards

No Fromage
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  #8  
Old 21 Aug 2014
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Quote:
Originally Posted by Big Yellow Tractor View Post
My mate's 690 is a right-royal PIA because you can't start it in gear.
It's probably the clutch-switch. It was changed to a new design a few years ago and the new design is even worse then the old. A cleanup, WD40 and some fiddling will usually fix it - for a while.
This is PIA on a high bike, esp offroad. I would have tried to find a better armature/switch.


Quote:
Originally Posted by Big Yellow Tractor View Post
I disabled both the sidestand and clutch switch on my DRZ within a day of buying it. So far I have managed not to ride off with the stand down or try and start it without the clutch in. I have always pulled the clutch in when starting anyway.
Like you I've disabled my clutch-switch, so the bike can start in gear without clutch.
But I will not recommend it.... If you buy accident hit the starter button or the starter-button fails (or a short-circuit in the starter circuit) in 100+km/h your starter will engage. The result will be a locked rear-wheel and a destroyed engine with flying parts
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Old 22 Aug 2014
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Quote:
Originally Posted by AliBaba View Post
Like you I've disabled my clutch-switch, so the bike can start in gear without clutch.
But I will not recommend it.... If you buy accident hit the starter button or the starter-button fails (or a short-circuit in the starter circuit) in 100+km/h your starter will engage. The result will be a locked rear-wheel and a destroyed engine with flying parts
If this should ever happen, I will be sure to post pictures of the destroyed engine and my X-rays on here :-)
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  #10  
Old 22 Aug 2014
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If you take out side stand or clutch switches, it might be worth looking at road worthiness requirements where you live, and have parts at hand to put the switches back temporarily before you take your bike for inspection ...
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  #11  
Old 12 Sep 2014
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Sorted !!!!
Well as suspected it was a side stand switch issue.

I purchased a bypass switch for £14 and the bike worked fine so i took it back to KTM and they sorted it under warrantee.

Pisses me off that the design is so prone to the introduction of an unnecessary fault but what can you do.

I will dig out the box that the bypass switch came in and post the part number as for £14 its a handy spare.

No Fromage
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