KTM 690 R gets Wired

Discussion in 'Thumpers' started by fire_strom, Oct 16, 2009.

  1. fire_strom

    fire_strom Long timer

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    For navigation and for heat.

    Like I do with all bikes I wanted to be able to power a GPS, a vest and heated grips.

    There's nothing earth shatteringly complicated about doing any of these things but I haven't seen much on the subject specifically relating to the 690's.

    So to start with I ordered some stuff from Powerlet and Symtec heated grips from CalSportTouring.

    [​IMG]


    I went with Symtec for the heaters for two reasons, one, the choice of switches and two, they have two circuits for high and low instead of some versions that use resistors to change from high to low (waste of power and pain to wire cleanly).

    I went with the metal toggle because I've preferred it in the past. In this application, with this location I might have opted for the little plastic one. Once I get the little rubber boot I'll be happier with this one.

    [​IMG]

    I had gone to the geek store (Radio Shack) and picked up a relay so I could avoid the inevitable dead battery from hot grips while parked scenario. Well once I got into the project I realized the nice engineers at KTM had given me ACC1 and ACC2 leads to work with under the headlight. One is always hot the other is switched with the ignition. I used the switched one and didn't bother using the relay. The ACC1&2 are both rated at 10A so my 3A grip heaters shouldn't tax them at all.

    Here's a picture.
    You can see the two red wires joined and connected to the brown wire in the center. They are the ground wires from the grips going to the ground from ACC2. The BLK/RED wire to the right of them is the hot (switched) going to the grip heater switch. I routed the wires along the path of the clutch hose.

    Attached Files:

    #1
  2. fire_strom

    fire_strom Long timer

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    I put the switch next to the ignition. It is mostly out of the way there and I think it will not interfere with the tank bag that usually goes there. There's a steering damper in my future and I am not sure if this location will work with the mounting of the tower but I'll update if it doesn't.

    You can see the wires following the path of the clutch hose in the left of the picture.

    Next up will be the GPS and Powerlet (BMW) socket wiring.

    Attached Files:

    #2
  3. .chris

    .chris 690 Advenduro

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    Nice job, I am about to do similar, but attaching a cigarette power adapter to my 690e.

    Just picked up a mates volt meter so I at least have a chance getting it right.
    #3
  4. .chris

    .chris 690 Advenduro

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    Had a play with the volt meter, and found this connector on the left side.
    http://picasaweb.google.com/lh/photo/2XcyX3JF_B6PxmE_Uj5wiA?feat=directlink

    It reports as being 12v, and is switched on the ingition,
    Any idea what type of connector that is? Would be nice to buy a connector for that, and wire it up to the cigarette power thingey, I really do not want to splice any wires or touch the bike any more than nessessary.

    Any advise/help appreciated.
    #4
  5. bobzilla

    bobzilla Dirty Old Man

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    Hey Firestrom
    Let me know when you get all that running at the same time and tell me if your stator keeps up. Thats exactly what I want to do. I have already removed the candle in the front and replaced it with a Baja 8" HID. The only other draw I have is the Garmin 60csx. I hope it will run the grips and the jacket too. Nice job BTW
    #5
  6. Biped

    Biped NooB Again

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    Looks like RIGHT side, connector to the solenoid valve used on the US bikes evap canister for emissions control. It is probably switched by the ECU so would not be on all the time while riding.
    #6
  7. .chris

    .chris 690 Advenduro

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    yeah sorry you are right, that is the right side.
    That would make sense being for the evap conister, as that connector seems rather convenient.

    I found the other 12v options up the front, so I guess I just run with that, seemed to be 4 of them, 2 of them were always on, the other 2 were switched. Just need the right connectors and away I go.
    Guess I run with that. Off to jaycar (downunder budget version of radioshack) when the weather is not so horrid outside.
    Shall document my setup once done, could be handy for other electrically challenged people who try similar.
    #7
  8. fire_strom

    fire_strom Long timer

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    Yup, that one does look like the evap deal.

    Hey .chris, I only saw two ACC leads (2 pairs of wires two + two -), where did you find the others?

    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    As for load on the bike, I figure the output should be ok to handle all of them. I read somewhere they put out 225w but I don't know if that&#8217;s true or not. <o:p></o:p>
    <o:p></o:p>
    the grips are 36w<o:p></o:p>
    the vest is 45w<o:p></o:p>
    the GPS is 7w<o:p></o:p>
    the headlight 35w (but I want to be able to burn 70w)<o:p></o:p>
    Tail light & parking light around 5w think.<o:p></o:p>
    That totals 163w w/ the 70w headlight. <o:p></o:p>
    That leaves 62w to charge the battery, run the computer stuff and the power the pump and what ever else it needs.<o:p></o:p>
    <o:p></o:p>
    I guess I don't really know what it needs for its critical processes. If that&#8217;s too close I can disable the parking light, and put an LED in the tail light for a few watt savings.<o:p></o:p>
    <o:p></o:p>
    Anyone know for sure what these are putting out?<o:p></o:p>
    <o:p></o:p>
    Scott<o:p></o:p>
    <o:p></o:p>
    #8
  9. .chris

    .chris 690 Advenduro

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    Sorry, my bad terminology causing confusion, there were only 4 wires total, so 2 sets of 12v
    #9
  10. Seth S

    Seth S Will _____ for _____

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    There are newer controllers for the heated grips that pulse a digital signal and do not draw the entire 45 watts. You might get one of those and cut your consumption down a little. As a rule of thumb I usually try to leave 100 watts to run the bike. With this bike you have the fuel pump, injector, computer, electronic ignition etc...62 watts may be undercutting the bike....meaning it may run for a long time but the charging system may not be covering the load...thus the battery will draw down over time. What we need are some specs on the current draw from the running systems of the bike. Also if you are drawing the full amount you are also cutting into your engine power and fuel mileage.
    #10
  11. fire_strom

    fire_strom Long timer

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    Both the real stator output and the real minimum requirements of the bike would be very helpful to know. For now I have a good buffer because the light is still the 35w stock one.
    Scott
    #11
  12. LowOnFuel

    LowOnFuel In the crapper

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    The OM says 224 W for stator output.
    #12
  13. fire_strom

    fire_strom Long timer

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    Next up is the Powerlet plug. It went smoothly. I Doubled up on the ACC so I could also wire the GPS to this one.

    I used the Low profile socket.

    [​IMG]

    I bought an extra connector that I didn't need as the kit comes with the other half of the modex type deal shown in the bottom left of the picture.

    It was a tight fit and there's a bit of interference with the seat (Renazco) but not much. Over all I'm happy with the placement.

    I ran the wires along the right side of the head tube and while doing so re-routed the wires from the grip heaters to that side too. Its cleaner this way and leaves the clutch hose plenty of room.

    I'll get to the GPS next and add more on this later.

    Scott

    Attached Files:

    #13
  14. Bearded Hooligan

    Bearded Hooligan Moto Addict

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    Nice write up about the grips:thumb The directions that came with the grips are bit difficult to read as mine are blurry from the copying. The two blue wires go to the switch and plug into the high and the white together go to the low? Then you just ran the power and the ground to the acc plug on the front, the plug I saw has two white wires, brown and a red with blue stripe. Is this the plug you used? Thanks
    #14
  15. fire_strom

    fire_strom Long timer

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    No, that plug is the mystery one I asked about in this thread>
    http://www.advrider.com/forums/showthread.php?t=516364

    The leads I used are the ones at the bottom (690 R) marked ACC. There are two sets one always hot (ACC1) and one set that is only on when the key is on (ACC2). They are marked ACCx 10A so if you dig around in there you should find them.

    Scott
    #15
  16. Bearded Hooligan

    Bearded Hooligan Moto Addict

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    Worked like a charm, thanks:thumb
    #16
  17. Bearded Hooligan

    Bearded Hooligan Moto Addict

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    Am I missing something? I know I am an electrical retard, but I think I have mine wired the same way that you show above. When I wire to ACC2 I get grips on all the time with the key, there is no off. Brown gets the two red to ground. The black/red gets the red from the switch which is plugged in on the middle plug for the switch. BLue to high and white to low = Smoking hot grips all the time. Anyone help an electrical newb?
    #17
  18. fire_strom

    fire_strom Long timer

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    Wierd, that sounds right. Are you saying that even with the switch in the middle position your grips are hot or that you can turn them on even if the bike is turned off?
    Scott
    #18
  19. Bearded Hooligan

    Bearded Hooligan Moto Addict

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    They are off when the bike is off but come on when the bike is on and cant be turned off even with the switch in the middle position.
    #19
  20. Bearded Hooligan

    Bearded Hooligan Moto Addict

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    Huh, just went and tried ever possible combination and put it back to the way that I originally had it and it works fine now. Go figure! See why I can never become proficient at electrics:deal
    #20