How to wire into '03 LC4 640 accessory outlets?

Discussion in 'Thumpers' started by BlitzBike, Feb 10, 2006.

  1. BlitzBike

    BlitzBike LC4 Pilot

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    May 6, 2004
    Oddometer:
    800
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    Ft. Lauderdale, FL near Alligator Alley
    HELLP!!! I was all excited to get some new electronics goodies only to find out that my male/female SAE plug does not match the Female/Female reciever plugs under the dash of the LC4. Is there somewhere (local automotive or KTM) I can get a male/male plug that matches the LC4 receptical? (not sure what they are called)
    I wanna go via these recepticals to clean up the wire mess on my dash and have my accessories "keyed" to the ignition switch.
    Thanks
    #1
  2. empedrado

    empedrado Been here awhile

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    I found the exact match for my 640 at an electronics part store here in town. They brand named Molex and distributed by GC/Waldom.
    #2
  3. BlitzBike

    BlitzBike LC4 Pilot

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    I see their website...you wouldn't happen to have a part number would you??
    #3
  4. creeper

    creeper Still alive...

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    2 thru 12 pin Molex connectors, male and female are available at Radio Shack... really. :D
    #4
  5. BlitzBike

    BlitzBike LC4 Pilot

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    Oddometer:
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    Ft. Lauderdale, FL near Alligator Alley
    Cool... I wish I had waited for a reply as I went ahead and fabed up my own using two single pin automotives taped together to make dual pin.
    Kind of hinky but it works. I'll go to radio shack now so I can enjoy the real thing!
    #5
  6. creeper

    creeper Still alive...

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    Replace them with Deutsch connectors if you want to get all waterproof and stuff. :evil

    I know... why did he have to show me those. Bastard!

    C
    #6
  7. BlitzBike

    BlitzBike LC4 Pilot

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    May 6, 2004
    Oddometer:
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    Ft. Lauderdale, FL near Alligator Alley
    Boy thats even sweeter if it weren't for the fact the factory left zero slack in the lines to work with making replacement that much harder.
    Damn why'd you show me those!! Now I'm really gonna work!
    What guage is the stock KTM wire????
    #7
  8. creeper

    creeper Still alive...

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    God told me too... said you needed a challenge in life. :wink:
    #8
  9. meat popsicle

    meat popsicle Ignostic

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    Everyone complains that is is merely "adequate"; some even aledge it is under-gauge... so whatevery you do, if you are replacing it, upgrade.

    Now who is the fella, beaver somethin'... :scratch
    Ah yeah! Eastern Beaver!!! :lol3 He sells nice stuff - perhaps you can get some good stuff from him if you can't source good components.

    No this is not a joke, just poor business name choice I guess. I don't think electric components when I read eastern beaver... I think of upstate NY girls in tight sweaters and... :tb
    #9
  10. BlitzBike

    BlitzBike LC4 Pilot

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    May 6, 2004
    Oddometer:
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    Location:
    Ft. Lauderdale, FL near Alligator Alley
    I just wanna know what guage the stock wire is so I get the appropriate plug guage. Never mind the upstate NY girls---been there, done that, and,
    found it to be the toughest crowd going---look elsewhere for happy hunting.
    #10
  11. meat popsicle

    meat popsicle Ignostic

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    Can't recall where the post was, but one user claimed an improvement in lighting performance by upgrading the stock headlight wiring... not out of the realm of possibility, I suppose.
    #11
  12. Stomp

    Stomp Imprisoned Wanderlust

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    I've got a '99 and want to wire up my GPS. I was thining of installing a socket in the dash, but I'm not positive that's the route I want to take or not. Regardless, I'm inquiring about the two connectors under the dash. They're swiched power, but the voltage is odd...something like 10.6 Vdc (12.8 measured at the battery). What's up with that? Anyone know if the inline voltage converter TT cables available for my GPS step that voltage down to 3V without any problems?
    #12
  13. Luke

    Luke GPoET&P

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    Should be no problem at all. The most common design for these voltage converters works on anything from 6 to 44 volts. Just make sure you get the polarity right. If you're worried about it, measure the output voltage of the converter before you hook up the GPS.

    The reason you're measureing 10.6V on the socket is because the stock wiring is junk. I saw a little less than 10V on my headlight bulb before I upgraded the wiring. Others have seen similar numbers. If you turn off/unplug your headlights, the voltage on the connector should go up considerably.
    #13
  14. KenR

    KenR Long timer

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    I just got done reworking the wiring on my 03 640 Adventure for my accessories. Ran 12ga. wire directly off the battery, positive and negative (fused the pos.), ran it up under the dash to a Centech AP1 fuse box then ran my grips, vest, GPS and roadbook off of that. Really cleaned things up.

    One thing I'm going to do that I didn't think of until I was done (duh) is install a master switch just before the AP1 to ensure I don't forget to turn something off and run the battery down. Easier to remember to hit one switch instead of four at the end of the day, plus it'll allow my grips and vest controllers to stay at preset levels.
    #14
  15. Stomp

    Stomp Imprisoned Wanderlust

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    Did you install a socket to power your GPS or some other connector? If I'd put a socket in, it would be in the dash...nice and close to the GPS. The issue is that the cables I can buy with the socket attached are 3 or 4 feet long. Maybe I should just buy a power cable sans socket and have some other easy to access connector? Not that the power wire would be coming out all that often anyway, but ya never know.

    Hey, Ken. Are you still looking for soft pannier racks for you 640? I've gone hard bags and can move my soft bags/racks out of my garage.
    #15
  16. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Ken- Don't bother with the switch to cut power to the Centech. I kept having senior moments by failing to switch off my grips, which were run through the Centech and more often than once did you find me using that old fashioned kick start lever instead of the electric kicker thanks to a dead battery.

    I wired a potted relay with a little mounting tab just aft of the subframe crossbar the seat bolt passes through. A relay was mounted to the top side of the rear fender, and the trigger or switch wire on the relay is tied into the positive wire that powers the tail light using a T-Tap.

    Voilas! Now, Turn on the key, and the relay is triggered, sending an abundance of clean, unadulterated DC power up to the Centech which powers the Gerbing, grips, Garmin, HID's, and a blender for roadside adult libations.

    PM me and I'll give you a hand. This particular wiring job is easy.

    Dirty
    #16
  17. OzAdvRider

    OzAdvRider EZrider

    Joined:
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    Oddometer:
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    Location:
    Adelaide, SA, Australia
    Hello CREEPER,

    I am a new AdvRider. I just bought a 04 KTM640 Adventure(5,600km). Thank you for the info on the DEUTSCH. I went to the web site but did ot now which model to buy. I am trying to power a GPS, 2 way radio, heated grips, aux light & 2 more aux appliances. Sure appreciate if any one can point me to a system ect.
    http://www.deutschconnector.com/cgi-bin/store/agora.cgi?cart_id=7993723.17596*AW3rK0&xm=on&product=DTP_2-Contact|DT_Sealing_Plug|Mounting_Accessories

    I sure would appreciate if anyone could point out to me which model to buy to fit my 04 640 dash board socket.

    I am wonderfully overwhelmed and hunbled by the members with the support and rich knowledge on these forums.

    Thank you Creeper and everyone here on this forum.

    Cheers,

    Willis
    #17
  18. creeper

    creeper Still alive...

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    You may want to rethink all that stuff... at least running it all at the same time.
    The LC4 has a 200 watt charging system... and that full 200 watts comes at a fairly high rpm. At cruise rpm, it's about 3/5ths that output.

    The generator / regulator output depends on engine rpm . Please see table below:
    • 1500 rpm 9 A
    • 2000 rpm 11 A
    • 3000 rpm 13 A
    • 6000 rpm 14 A
    • 10000 rpm 15 A
    (Above borrowed from a Flanny post... who got it from a KTM electrical engineer)

    Using a cruise rpm of 5000 or so, and an average output of 13.5 amps... you'll need 3.5 amps for your battery, so you want to have a total draw of no more than 10 amps, preferably less... and that includes your stock lighting and ignition system.
    Your headlight pulls a bit less than 5 amps, another couple amps for the remaining lights and ignition. That leaves about 3 amps available for accessories.

    So you may want to start adding up the draws of all your goodies to determine what you can have on... and when.
    Like for example if you're poking around town and have heated grips and non-HID aux lighting on... your total draw will exceed your output and your battery will no longer be receiving and adequate charge.

    Back to the drawing board huh? :lol3

    Oh yeah... the male plug you need to fit the 10A unswitched accessory socket is made by Powerlet.

    C
    #18
  19. OzAdvRider

    OzAdvRider EZrider

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    Oddometer:
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    Location:
    Adelaide, SA, Australia
    Hi CREEPER,

    Thank you! Back to the drawinng board:eek1 esp with all the pertinent info you written. Thank you!

    EZrider

    #19
  20. rjf

    rjf SBS's #1 fan in January

    Joined:
    Nov 21, 2004
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    Location:
    Gosford, NSW, Aust. Scrambler, 640Adv, 300EXC
    The easiest way to get a plug that fits the socket in the dash is to get one from a BMW stealership. I had the BMW part #, cannot find it, I'll post it if I do.
    #20