Least destructive KTM PP LED blinker install on '06 SD Pics

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nitro450exp
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Least destructive KTM PP LED blinker install on '06 SD Pics

Postby nitro450exp » Thu May 07, 2015 10:29 am

Hello,

So when I bought the SD used, it came with RR peg sliders and KTM Power Parts LED turn signals that were not installed.

It turns out the rear peg pins are knurled and pushed in.
I was able to get them out and install the sliders using a clamp and socket.

The LED Turns were another story, no easy fix.
I do not want to cut the Factory harness.

The Problems:

1. The LED turns have JST micro connectors.
2. The accessory power feed on the '06 is under the seat not in the mask.
3. The rear turns are hard wired and combine in a Molex 4 Pin connector under the seat.
4. The front turns are hard wired, and terminate in a Molex 12 Pin, under the speedo.

My Options:

1. Rear Turns, Make a jumper in the rear with 4-Pin Molex on one end and 2 JST connectors on the other end. (plug and play)
2. Power feed, Make a feed jumper wire that feeds from under the seat up into the mask ( Spade connectors that match the KTM harness) (plug and play)
3. Front turns (Opt 1) Make another Molex jumper for the front, pull the Molex pins from the 12pin and remove with old turns. Put jumper pins directly into 12 pin Molex and have 2 JST on the ends. (Rearrange, plug and play)
4. Front turns (Opt 2) Cut the factory harness and install JST waterproof connectors on the factory harness. (plug and play) However I will add JST connectors to the old turns, thereby making them plug and play should I decide to remove the LED turns.

Additional comment: I chose option 2 on the front turns, despite my comment not wanting to cut the factory harness, here is why.
The wires coming out of the front turns splice into the main harness and go up to the speedo and down to the 12 pin main connector, probably part of the indicator lamp system or the turn signal switch itself. As a result option 1 would have required splicing as well as swapping out pins.
The next owner probably would have come after me with a lynch mob.
I say next owner because I always approach my mods and customization so that I can restore the bike to factory when I move on, I have yet to move on, I seem to collect instead.

The execution:

First I needed an assortment of connectors and tools and supplies.

Being that I have just moved to France and did not bring much in the way of tools or supplies, I looked online.
I found cycleterminal.com in the USA, he had the Molex, 6.3mm Spade and JST connectors and pins.
He also has an assortment of crimp tools.

Upon discussion with Joe, he offered to help reduce my cost,(buying 3 different crimp tools would be needed) by assembling the Jumper harness and Molex Jumper.
I agreed to have the Molex to JST and 6.3mm Spade to 6.3mm double barrel jumper made.
At the last minute I had him add another 6.3mm Double Barrel on the spade end of the jumper, so that after using the factory Acc. 1 connector, I would still have an Acc. 1 under the seat.
This now meant that I only needed one crimp tool and the JST male and female connectors for the front turns (opt 2) cut and install waterproof JST Micro connectors.

I am tracking the package and will update with pictures and How to instruction when I do the install.

Regards
Nitro

Update 5/11/2015

Parts and tools arrived today.

Image
1. PA-20 Crimp tool.
Image
1. Ground Jumper cable.
Image
1. Molex to JST Jumper.
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2. JST M/F connectors and pins (Extra Pins to get the hang of the tool. )
Image


Image
I only put 1 blinker in the picture.
Power parts Kit
2. RH LED Blinkers
2. LH LED Blinkers
1. LED DC Flasher.
1. LED Flasher Harness.

Nice clean execution, just like I would have done it (or at least it would have been my target.) Yes I am anal.
I really like it when someone takes pride in their craftsmanship.
I know I paid to have these parts made, but not that much. (I think)
And lately even when paying good money I have received crap.

I will layout everything and get pictures posted.
I plan to Install this Thursday, Bank holiday in France. (I hate this secular PC shit, just call it a fu@king religious holiday.)
Sorry to rant but the PC shit is getting crazy, when does common sense come back ?.

Nitro.

nitro450exp
Two wheeled terror
 
Posts: 190
Joined: Mon Apr 13, 2015 2:11 pm
Location: Here

Re: Least destructive KTM PP LED blinker install on '06 SD P

Postby nitro450exp » Fri May 15, 2015 7:16 am

Sorry no Update.
Rained most of the Day.

No Garage to work in.

Nitro

5/16/2015

Sorry got shipped out of town for work,
will be back in two weeks.

Nitro
2006 KTM Super Duke LC8
2000 Honda RVT1000RR (SP1, RC51)
2009 Aprilia Tuono 1000R
WERA # 661 (Retired)
WERA Endurance # 66 (Retired)

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bruders8146
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Posts: 210
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Re: Least destructive KTM PP LED blinker install on '06 SD P

Postby bruders8146 » Mon May 25, 2015 11:02 am

I've done this a few months ago on my 06 model

you don't need to access the accessory terminal under the seat everything can be done under the mask!

What I did with all the led indicators was to cut the little white connector off and solder on some extra cable ( don't get much to work with) I don't belive you need to do this for the 08+ as they already have the connectors (this does need to be confirmed)

With the rears I cut existing loom and just soldered the rear led to the plug.
did the same to the fronts

Then wrapped up in electrical tessa tape.

The relay is pretty much plug and play the only drama is finding an earth. I just piggy backed it from the indicator loom.

Hope that helps alittle
Image
Image
Image

Then this is the look after I upgraded my mask
Image

nitro450exp
Two wheeled terror
 
Posts: 190
Joined: Mon Apr 13, 2015 2:11 pm
Location: Here

Re: Least destructive KTM PP LED blinker install on '06 SD P

Postby nitro450exp » Mon Jun 08, 2015 7:59 am

Hello,

So I take apart the tidy tail and get ready to install the rear blinkers.
Oh Oh.
The 4 pin Molex that I assumed was the blinkers ( 2 ground 2 lives) is in fact,
1 common ground 2 lives (blinkers) and 1 live (Lic. Plate light)
The harness splices all 3 grounds together (L and R Blinker and Lic. Illumination)

Needless to say, looks like I will have to cut the factory wires.

Nitro out
2006 KTM Super Duke LC8
2000 Honda RVT1000RR (SP1, RC51)
2009 Aprilia Tuono 1000R
WERA # 661 (Retired)
WERA Endurance # 66 (Retired)

nitro450exp
Two wheeled terror
 
Posts: 190
Joined: Mon Apr 13, 2015 2:11 pm
Location: Here

Re: Least destructive KTM PP LED blinker install on '06 SD P

Postby nitro450exp » Tue Jun 16, 2015 8:44 pm

Ok I decided to just cut the wires and do the JST waterproof connectors.
Will post pictures this weekend.
I hope.

Nitro
2006 KTM Super Duke LC8
2000 Honda RVT1000RR (SP1, RC51)
2009 Aprilia Tuono 1000R
WERA # 661 (Retired)
WERA Endurance # 66 (Retired)

nitro450exp
Two wheeled terror
 
Posts: 190
Joined: Mon Apr 13, 2015 2:11 pm
Location: Here

Re: Least destructive KTM PP LED blinker install on '06 SD P

Postby nitro450exp » Sat Apr 23, 2016 1:24 pm

Filally done.
Will post some pics after uploading.
Cut wires crimped terminals and WP connectors.
It is now plug and play.
All correct plugs from later model KTM.

Nitro

Image

Image

Image
2006 KTM Super Duke LC8
2000 Honda RVT1000RR (SP1, RC51)
2009 Aprilia Tuono 1000R
WERA # 661 (Retired)
WERA Endurance # 66 (Retired)


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