2023 KTM Wiring Harness Failure

AssangeMX wrote:

It's the brass part on side of cylinder,  only $20 so worth trying before buying a new harness and fuel pump lol!!! Use a bit of...

It's the brass part on side of cylinder,  only $20 so worth trying before buying a new harness and fuel pump lol!!!

Use a bit of dielectric grease on connectors

cwolf96 wrote:

I'm almost certain I found my issue.. hopefully it can be helpful for others.  Just like the OP posted and the picture he used, my frame...

I'm almost certain I found my issue.. hopefully it can be helpful for others.  Just like the OP posted and the picture he used, my frame wore through (3) wires that feed down to the Throttle Body.  If you remove the tank and follow the main harness, there's a metal tab welded on the inside of the frame tube, a zip tie is fed through to keep the main harness tight against the frame and that's what wore through the wires.  Hopefully some others can look at theirs and stop a potential issue.  

cwolf96 wrote:

I'm almost certain I found my issue.. hopefully it can be helpful for others.  Just like the OP posted and the picture he used, my frame...

I'm almost certain I found my issue.. hopefully it can be helpful for others.  Just like the OP posted and the picture he used, my frame wore through (3) wires that feed down to the Throttle Body.  If you remove the tank and follow the main harness, there's a metal tab welded on the inside of the frame tube, a zip tie is fed through to keep the main harness tight against the frame and that's what wore through the wires.  Hopefully some others can look at theirs and stop a potential issue.  

boolzi wrote:

I absolutely know the exact spot you’re talking of well, very well. When it was newer i put a peice of foam there and re-zip tied...

I absolutely know the exact spot you’re talking of well, very well. When it was newer i put a peice of foam there and re-zip tied it. But as i still couldnt get rid of my bog issue last week i completely cut my harness open. It’s all in great shape. But that spot where your talking about does look like an issue, there should be nylon fabric sheath under the tape that makes it difficult to damage wires where it rests against the tab. 

 

On edit, are your damaged wires in the main bundle or the branch in the small plastic sheath that goes to tps?

AssangeMX wrote:

It's the brass part on side of cylinder,  only $20 so worth trying before buying a new harness and fuel pump lol!!! Use a bit of...

It's the brass part on side of cylinder,  only $20 so worth trying before buying a new harness and fuel pump lol!!!

Use a bit of dielectric grease on connectors

AssangeMX wrote:

AssangeMX wrote:

jackcolombo wrote:

I think i ordered the right one. Thanks a lot. It just screws in? It always happens when the bike is hot. So it's always hard...

I think i ordered the right one. Thanks a lot. It just screws in? It always happens when the bike is hot. So it's always hard to duplicate. I've changed everything! Stator, plugs, fuel pump, piston, battery, all filters etc... Fingers crossed on this or next try is wiring harnass. I will send you a gift if this works lol. i literally asked the KTM dealer if there are any sensors when hot that could cause anything. They charged me a $1000 in labor for nothing, said they went through everything. I gave up and brought to them Pushed my bike 5 miles through sand and whoops on Sunday. 

AssangeMX wrote:

AssangeMX wrote:

alexrodriguez wrote:

Any luck with the water sensor? Same problem

jackcolombo wrote:

Can you tell me the part number for the coolant sensor? This is my exact problem. It's driving me nuts for a year. I've changed everything...

Can you tell me the part number for the coolant sensor? This is my exact problem. It's driving me nuts for a year. I've changed everything but the wiring harnass. I'm about to order one. I wanna try this first.