Ken S 164 Posted January 1, 2019 Bike completely shut off today. Fortunately 1/4 mile uphill from the truck. 2018 500 Ground wire from the battery to the frame smashed by the seat pan. I will be doing a double ground wire setup. If you have one of these bikes check it and fix it before you have this issue in a bad place. 1 Share this post Link to post Share on other sites
97xr400r 122 Posted January 2, 2019 Amazing it would cause it to shut down, it's not even severed. Thanks for sharing, more grounds sounds like a great idea. Share this post Link to post Share on other sites
simicrintz 177 Posted January 2, 2019 How did you find it? Share this post Link to post Share on other sites
Ken S 164 Posted January 2, 2019 Took off the seat. Wiggled it and the fuel pump kicked on. I was surprised a partially severed ground killed everything. Share this post Link to post Share on other sites
simicrintz 177 Posted January 2, 2019 Nice catch. That coulda been tough to find. Cool when the issue presents itself quickly! Share this post Link to post Share on other sites
amgems 79 Posted January 2, 2019 Wow. Shows how important a solid ground is. Thanks for the alert. Share this post Link to post Share on other sites
Covered in Dust 162 Posted January 2, 2019 Van had a loose ground wire on his 2017 when he got it. Easy fix once he found it but it was concerning when we were on the trail in New Mexico. Share this post Link to post Share on other sites
kkug 145 Posted January 2, 2019 Might have to double washer the ground lug and use a shorter bolt. The bolt may bottom out in the blind nut in the plastic fender . and yes got to swing the ground wire over so the seat plastic does not smash it . Share this post Link to post Share on other sites
Bp619 102 Posted January 2, 2019 I noticed that other day on my 17 450, that the seat pan was smashing it. Will do the same as well thanks Share this post Link to post Share on other sites
Bagstr 287 Posted January 2, 2019 ?? I suggest the seat was stretching the terminal connection. Unless you have a completely open ground. Share this post Link to post Share on other sites
Bp619 102 Posted January 2, 2019 17 minutes ago, Bagstr said: ?? I suggest the seat was stretching the terminal connection. Unless you have a completely open ground. Heres a reply from the facebook post kenny shared seems light might make some sense. "The ground wire is compromised, and the current tries to short through the paint in the frame, rather than follow down to the grounding point. This makes the DC circuit incomplete, and the ECU shuts off. It has to see 12+ volts on the plus and minus, or it won't function." Share this post Link to post Share on other sites
tntmo 882 Posted January 2, 2019 Good catch. I have seen a lot of mystery electrical issues caused by poor grounds. Share this post Link to post Share on other sites
robertaccio 405 Posted January 2, 2019 we are in the digital age. those little power glitches/spikes/resistance/impedance changes etc can trigger all kinds of digital mayhem...at least in this case the machine doesn't fall from the sky..... 1 Share this post Link to post Share on other sites
simicrintz 177 Posted January 3, 2019 Went out to the garage and pulled my seat a coupla minutes ago; same thing starting to appear! Rerouted (hopefully this will keep from anymore chaffing). Can't believe we are the only ones experiencing this and that KTM does not know about it!! Thank you again for the heads up, Ken; you very well may have saved me and others from being stranded much farther from our trucks! Share this post Link to post Share on other sites
paulmbowers 236 Posted January 3, 2019 Yup- I've been keeping and eye on mine- it's in a difficult spot. I'd hoped to drip/tap a new spot, but it's hard to get a drill in one of the vertical parts of the subframe. Not to mention weakening the subframe.... Share this post Link to post Share on other sites
simicrintz 177 Posted January 3, 2019 Can you roll yours up and over like I was able to, Paul? It's hard to say but I think I've gotten it out of the way pretty good. I like the idea of a double ground but don't know where I would go either. Share this post Link to post Share on other sites
paulmbowers 236 Posted January 3, 2019 35 minutes ago, simicrintz said: Can you roll yours up and over like I was able to, Paul? Not exactly- my bike is older (legacy, vastly superior, they don’t make ‘em like they used to) and has a different subframe. I’d have to move the ground to a very different spot. And since I’m lazy, no good, and will never amount to anything (I love you mom) it will likely not happen. Not soon, anyway. Share this post Link to post Share on other sites
simicrintz 177 Posted January 3, 2019 Yes-2014; I remember the good ole days! Got to stay out until the porch light came on. I sure do miss those days...... Share this post Link to post Share on other sites
Ken S 164 Posted January 4, 2019 Crimped and soldered smaller terminals onto automobile type ground cable. Ill put the OEM ground strap on as well when it comes in. Probably overkill. I like overkill. I may run a 3rd ground to the starter. Plan on riding this bike for years and hate breakdowns. 1 Share this post Link to post Share on other sites
kkug 145 Posted January 4, 2019 I see you guys have a new spot where they attach the ground to the frame. Share this post Link to post Share on other sites
amgems 79 Posted August 9, 2020 KTM riders - Check your ground straps! My bike died Friday. Just completed a 75 mile loop. It quit 2 miles from home. Bike just stopped running. It would start with the kicker and run for a few seconds then quit. It would not do anything with the electric start button. Pulled the seat and realized I had not yet fixed the crappy ground wire attachment setup that was provided by the brilliant Austrian engineers on my $10,000 motorcycle. The screw that attached the ground strap to the frame was really loose. My theory is, because it was hot, the screw, that was screwed into the hot soft plastic fender came loose. Pretty weak design. The one on the other side was loose too. Fixed it with a beefy sheet metal screw. Share this post Link to post Share on other sites
Bagstr 287 Posted August 9, 2020 Mr. Amgems, May I suggest a threaded hole and machine screw. That aluminum is soft. Good item for periodic check. Mr. Bagstr Share this post Link to post Share on other sites
amgems 79 Posted August 9, 2020 Mr. Bagstr, I thought about drilling and tapping the hole and using a machine screw. I went with a sheet metal screw with the thinking that the coarse deeper threads would bite better into the thin soft aluminum better than the fine shallow threads on a machine screw. It did bite really well and I was able to snug it up nicely. Way better than the original screw into the plastic (sheesh how dumb). I will keep an eye on it, and the hole is small enough that I could go up a screw size or two if I do need to switch. I would also like to say, thank you for keeping this conversation properly formal. Mr. Amgems Share this post Link to post Share on other sites
paulmbowers 236 Posted August 10, 2020 During my recent bike refresh, I was able to relocate the grounding point by drilling and tapping a hole on the front side of the subframe crossbar. That accommodates the stock (modified- soldered and heat shrink) grounding strap and another ground for both a charging pigtail and accessory circuit. I reused the original location by approaching from the underside with a secondary ground wire that runs to the starter mounting bolt. That leaves the crossbar completely clear for the seat to rest on. 1 Share this post Link to post Share on other sites