2012 TE 310 trying to start in gear

[Mike-AK]

I suppose this is a gear position sensor issue, right? First the fuel sensor wiring, now this...hopefully KTM will be able to solve the Husky quality control issues.

 

[Johnrg]

Gear position or clutch or anything should simply affect the starter itself, not running or affecting a bump start. Maybe it's your kill switch. What happened w/ the fuel sensor wiring? The '13 bump starts like a dream though I should not be having to do that so much anymore.

 

[Mike-AK]

Starts fine. Problem is it tries to start in gear with the clutch engaged so the bike lurches. Not supposed to do that. Not sure what else the gear position sensor impacts, but a bike with 20 hours on it should not be having this problem.

 

[Johnrg]

I was only aware of a clutch switch on the 13. Not going to try starting mine in gear to test if I have a gear pos. sensor ;-) In the old days we were free to start in gear, fall over our kickstands, etc... I sort of liked it that way.

 

[Mike-AK]

I don't mind the bike lurching forward if I am dumb enough to hit the switch with the bike in gear, but I think the "Idle Transponder Assembly" does more than just work as a starter safety interlock. Also, it's not supposed to do that, so just one more thing wrong with the crappy Italian wiring on a relatively new bike. I have been told that Italian Husqvarna workers read posts on this board, and I should be careful about posting things that would be offensive to them. My response is that its pretty f$%king offensive to have failures on a bike with under 20 hours on it. Rant over.

 

[Johnrg]

Bummer to hear it Mike. Figured the only thing missing/out of order for you was that Shark Fin that never arrived or got sold to someone else;-)

Venting is therapeutic in any regard. A well focussed rant/vent sometimes gets to the root of the issue eventually.

 

[Mike-AK]

Bummer to hear it Mike. Figured the only thing missing/out of order for you was that Shark Fin that never arrived or got sold to someone else;-)

Venting is therapeutic in any regard. A well focussed rant/vent sometimes gets to the root of the issue eventually.

I've got my shark fin. Motosportz is first rate. No problems there. My concern is the wiring problems that seem to be endemic on these bikes. No big deal if all you do is go around in circles on a motocross track, but try getting stuck with a bike that won't run 40 miles from the trailhead out in the Alaskan bush.

 

[Johnrg]

I've got my shark fin. Motosportz is first rate. No problems there. My concern is the wiring problems that seem to be endemic on these bikes. No big deal if all you do is go around in circles on a motocross track, but try getting stuck with a bike that won't run 40 miles from the trailhead out in the Alaskan bush.

That looks great. Special order for the natural or satin anodized (didn't we vote on color months ago)? I hear you on getting stuck. Why I was a little put off myself until I got my issues sorted.

 

[Boogie]

Starts fine. Problem is it tries to start in gear with the clutch engaged so the bike lurches..

Does the starter work when the bike is in neutral and the clutch lever is NOT pulled in?

 

[OlderHuskyRider]

Isn't this a function of the the clutch interlock which is mounted on the clutch perch?

 

[OlderHuskyRider]

I don't mind the bike lurching forward if I am dumb enough to hit the switch with the bike in gear,

Isn't this a function of the the clutch interlock which is mounted on the clutch perch​

 

[Mike-AK]

Isn't this a function of the the clutch interlock which is mounted on the clutch perch​

No microswitch on the clutch lever. There is one on the front brake for the brake light, but no switches on the clutch perch or wires leading from it, only a stainless mesh hydraulic hose going to the clutch slave.

 

[OlderHuskyRider]

No microswitch on the clutch lever.

That makes your bike like mine, my bike will lurch forward as well, I almost always have the clutch pulled in when I hit the starter, I usually leave the bike in gear when turning off the bike. Odd that a TE doesn't have the clutch micro-switch.

 

[Mike-AK]

On the parts drawing it shows microswitch wiring, but there is nothing going to the clutch lever or perch. Maybe they left something off when they built mine? The only thing I can see coming from the area of the slave cylinder is the hydraulic line and the gear position sensor wiring. I'll take a closer look tonight. Maybe there is something coming off the slave cylinder somewhere.

 

[reveille]

Sounds like clutch drag, mine did it too but I switched to the Mobil 1 0-40 Euro and it stopped that problem. I put on over 40 hours last week riding it for 8 straight days. Running perfect

 

[Kawagumby]

Sounds like clutch drag, mine did it too but I switched to the Mobil 1 0-40 Euro and it stopped that problem. I put on over 40 hours last week riding it for 8 straight days. Running perfect

Didn't he say the clutch was "engaged"?
Am I way off here, but what's the problem? If the clutch is disengaged, then - I'd be looking at clutch drag. On my TE310 I soldered the clutch disconnect wires together so I could start while in gear like any other dirt bike.

I once had a bike slip off a narrow trail down a steep slope (just a foot or two, but no way could I get on or below the bike). Luckily for me, that pesky clutch safety switch had been bypassed and I was able to lean the bike toward me enough to hit the starter and starter drive that bugger back up onto the trail. (I would have been big-time screwed if that didn't work) That's a plus in my book...LOL...
Having to pull in the clutch to start the bike is mind-boggling to me. But what do I know?

 

[Mike-AK]

I'm not so concerned with it trying to start in gear as I am with the electrical system failure that is causing it. The worry is it will lead to a no-start condition and leave me stranded out in the bush with the bears.

 

[Kawagumby]

I see your point, but I'd bet it is a mechanical contact somewhere that isn't closing or conducting - not likely a solid-state device mass-failure kind of thing.
you said:

"The only thing I can see coming from the area of the slave cylinder is the hydraulic line and the gear position sensor wiring"

On my 09 the wiring goes directly into the master cylinder perch.
Are you sure that wiring doesn't lead to a microswitch? The only reason it would be there is to go to a switching device. I bet that switch is the issue - adjustment or failure....

 

[Boogie]

Clutch microswitch... It's so micro, it's hard to see.
You might have a micro rock jamming your microswitch into closed position.

This switch is "normally open" so failure would normally mean your starter system won't operate with your clutch lever pulled in (disengaged) or left out (engaged).

 

[Mike-AK]

Clutch microswitch... It's so micro, it's hard to see.
You might have a micro rock jamming your microswitch into closed position.

This switch is "normally open" so failure would normally mean your starter system won't operate with your clutch lever pulled in (disengaged) or left out (engaged).

Thanks. Where is it? There are no wires coming from the clutch lever or reservoir. Is it on the slave?