Broken/loose wire on 2017 ktm 350 but still runs the same

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8/7/2017 5:06 PM

I found this when I washed the bike yesterday. It ran normal at the track and when I started it after washing. What is it, where does it go, and what does it do?Photo

Photo

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8/7/2017 5:28 PM

Can't tell much from photo.

Paw Paw

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8/7/2017 8:07 PM

Check to see if it's the sensor wire going into the airbox

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8/7/2017 11:04 PM

Where does the other end of the wire go?

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8/8/2017 1:04 PM

RockyRider wrote:

Check to see if it's the sensor wire going into the airbox

Photo

I think you are right because I found this broken connection on the front of the airbox. What does it do and what is the risk of riding without it connected?
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8/8/2017 1:09 PM

Air temp sensor

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8/8/2017 2:26 PM

There's not much risk in riding without it connect, but the bike might not run 100% perfect. That sensor lets the bike know the temperature of the air entering the engine. I'd assume so the bike can adjust the air fuel mixture.

Is there enough wire to solder the wire back to the connection? The problem is that the grey piece is part of the wiring harness which cost about $300. It's not the actual sense thats broken, its the connector to the sensor.

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8/8/2017 3:06 PM

CarlinoJoeVideo wrote:

There's not much risk in riding without it connect, but the bike might not run 100% perfect. That sensor lets the bike know the temperature of the air entering the engine. I'd assume so the bike can adjust the air fuel mixture.

Is there enough wire to solder the wire back to the connection? The problem is that the grey piece is part of the wiring harness which cost about $300. It's not the actual sense thats broken, its the connector to the sensor.

X2

Paw Paw

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8/8/2017 6:09 PM

CarlinoJoeVideo wrote:

There's not much risk in riding without it connect, but the bike might not run 100% perfect. That sensor lets the bike know the temperature of the air entering the engine. I'd assume so the bike can adjust the air fuel mixture.

Is there enough wire to solder the wire back to the connection? The problem is that the grey piece is part of the wiring harness which cost about $300. It's not the actual sense thats broken, its the connector to the sensor.

Thanks so much for the help guys. There's barely any wire left in the connector but I'm still going to try to solder it. I'll probably hold off on getting a harness because it seems to run ok and I think it's been this way for a while. I guess we'll see how it runs this winter when it's 35 degrees and maybe fix it then.

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8/9/2017 3:14 AM

Dont try to run it when it gets very cold without that sensor. Summer is ok.

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8/9/2017 4:51 AM

That happened on my 450, ended up buying a generic piece from a streetbike that fit, cost was close to nothing. The bike ran ok with it broken, had no choice really since it broke on the way to the start of a +3 hour off road race. It was around 10 degrees celsius that day for reference.

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8/9/2017 9:07 AM

Lynch wrote:

That happened on my 450, ended up buying a generic piece from a streetbike that fit, cost was close to nothing. The bike ran ok with it broken, had no choice really since it broke on the way to the start of a +3 hour off road race. It was around 10 degrees celsius that day for reference.

Can you point me in the direction of the part you used? I haven't had much luck trying to solder the nonexistent leads left on mine. Thanks for the help

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8/9/2017 10:11 AM
Edited Date/Time: 8/9/2017 10:11 AM

search vital, busy at work, but had similar issue on kx450. Youc an source the connector for like 4$. take it off and post a photo, if its the same i can get you a place to order and part #. If not, i can get you to a site where you can find the proper connector. Looks like a sumitomo just like the kx. i have part # and site listed in response to somebody who had the same problem on here.

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8/9/2017 2:16 PM

The connector itself is just a weather pack connector- the green colored rubber part can slide out and expose the inside of it.

The terminals themselves (what the wire is attached to inside the connector) slides into a hole and clips into position. You can remove the terminal if you are careful (push the tangs back) and either replace it with a new one, or carefully open it up and remove the broken piece of wire, then re-crimp the good wire back into place. This is difficult to do without breaking it though.

This is basically what you are working with

Photo

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8/9/2017 9:10 PM

Well, I fixed it. I took the coupler with the broken wire off the sensor. The sensor itself has two prongs sticking out of it to connect the coupler. I took 2 generic round wire connectors and smashed them in the vice to make them fit snugly on the prongs. I then put the 2 wires in their respective places and crimped and soldered the connection and taped the shit out of it. I just removed the coupler that attaches the wiring harness to the sensor by connecting the wires directly to the sensor. The fi light is no longer flashing error can't sea and the bike seems to idle more crisply. I'm going riding tomorrow so I'll have to see how it holds up. Thank you to everybody who helped me fix this problem.

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8/10/2017 6:17 AM

Awesome smile

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3/18/2019 4:58 PM
Edited Date/Time: 3/18/2019 4:58 PM

I have same issue Just noticed today Red wire not connected, This must be a KTM issue 2018 350SXF. I am going to try and solder. I a live in Florida weather is never really cold. I honestly can't see how this happened. BAD location is my guess.

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