Plugs and Wiring

cniedwor · Aug 28, 2016

I'm planning to install an extra mini break-/taillight since my sw-motech alu rack will probably obstruct the main lights quite a bit once it's installed. I was hence thinking about making my own little splitter adapter to allow installing a little led light (which uses simple round plugs) in parallel to the main rear light without modifying the wiring of the bike. I hence spent some time studying the wiring and found the following things which may be of interest for others (if they are already hidden in some other posts, please excuse this):

- You can find the wiring diagrams in the repair manual (posted here)
http://www.ktmduke390forum.com/forum/service-maintenance/1810-ktm-duke-390-self-study-manual-5.html

- The wiring diagram codes are explained on this page in the RC390 forum:
Wire Diagram Explained
Wire Diagram Explained_zpsaxeffeyh.jpg Photo by DCMoney22 | Photobucket

- Especially important: This image shows you how to find the connector codes for the plugs/sockets!

- Now with these codes, you can use this KTM 2015 connector catalogue:
http://www.ktmshop.se/documents/9ff201fc65ded721d4cd0bcf7ba40af9.pdf

- This should give you the part number you need to order any plug and allow you to double check if it makes sense (design, number of connections etc...). Usually the part number will be 000700000XX - where the XX is replaced by the connector code from the wiring diagram

Most of these connectors seem to be quite cheap, so if you prefer keeping your wiring loom neat and clean, this should allow you to make any adapter/splitter/custom harness you please. HOWEVER, I don't have my connectors yet, so I don't know if you need any crimping tools to use them.

Cheers,
Christian

Diploman · Aug 28, 2016

A much simpler, easier and very secure way to make custom wiring harnesses is to use Posi-Tap connectors. They require no crimping, no bespoke matching connectors, do not damage the OEM wiring into which you are tapping, and are extremely easy to use. I have used them for decades with excellent, foolproof results. Highly recommended.

Posi-Tap- No Crimp Tap

cniedwor · Aug 28, 2016

I agree, that's much simpler, but I just don't like the look of tapped wires. By their very nature, these connectors will puncture the insulation of the OEM harness and after you remove them the harness is still punctured.
But just out of curiosity, why do you prefer the PosiTap ones over the standard 3M or scotchlok taps? (which are the ones I tend to use when I can't be bothered to make a custom harness)

Diploman · Aug 28, 2016

Compactness, secure connection, ease of use and minimal damage to OEM wiring. If you take off a Posi-Tap, the insulation at the tapping point will only have a tiny puncture, easily sealed with a drop of silicone sealer or a wrap of electrical tape.

I'm curious why tapped wires would offend your aesthetic sensibility, since they are invisible unless the bike is disassembled.

cniedwor · Aug 28, 2016

Sounds alright, I guess I have seen too many badly bungled together pieces of custom electronics

. But don't worry, I'm the first to admit that this is a bit ocd.

Ede · May 29, 2018

Thanks for the info.
I checked the Duke 2017 wiring diagram and there are connectors codes which are not in connector catalogue from the link above.
Does anybody have a link to an updated catalogue?

This is part of the wiring diagram for the rear indicators with "unknown" connector codes:

42569 · May 29, 2018

wouldn't those be the resistors for the LED indicators ?
(don't shoot me if I'm wrong it's been a while since my school days..)

Ede · May 29, 2018

According to the manual P45 and P46 are the rear indicators.
According to the beginning of this thread I am pretty sure that the codes are for the connectors.
Maybe the resistors are in the indicators or maybe the current is regulated by the unit which sends the electricity to the indicators.

Plugs and Wiring

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