wiring harness cable and connectors

[WesleyDRZ400]

Hi I am renewing a wiring harness on a ktm 640 and rather than buy a tatty one of ebay I think I will just do it myself.


which cable is preferable choice, 2mm 2.5mm or 3mm single core 12v?

Also what connectors are recommended by someone who has made a harness loom before

Cheers

[Snaf MKII]

I've built a few motorsport and machinery looms over the years and one for a Beta 350RR
0.25 would do for most of the loom but you need to work out what load everything is taking. For instance the the headlight would be about 7amps and would need 0.5 but each indicator would be 1.3amps and only need 0.2. Obviously starter, charging and ignition would need a much heavier gauge.
I'd pin the loom out on a large board and measure each each wire gauge as I stripped it down and replace like for like. Don't be tempted to use a heavier gauge than required or you'll get in to routing problems when you put it on the bike.

What model 640 is it, wiring looms are not that expensive from KTM if they are still available.

[Hugh]

Greetings,

Totally agree with Snaf MkII but may I just add a reminder that you label each wire before you disconnect it. Additionally take a photo on your phone of the connectors and the route of the cables. I tended to be generous with the length of each cable length just incase I needed to modify a connector or such.

TTFN

Hugh.

[IanB]

I agree with Snaf and Hugh.

It looks like they are still available from KTM new, @ £306

The enclosed file might be helpful to source any connectors which you might need to replace.

KTM OEM SpareConnectors.pdf

(376.22 KiB) Downloaded 136 times

[Brenhden]

I agree with Snaf and Hugh.

It looks like they are still available from KTM new, @ £306

The enclosed file might be helpful to source any connectors which you might need to replace.


KTM OEM SpareConnectors.pdf

Sounds like a lot of money, but if it works straight out of the box you can bank it against the number of hours work it would take to build one and fault find etc. It depends what you think your time is worth...

[bill_qaz]

Why renewing the harness why not just repair any damage and replace any connectors required?

[Crossrutted]

IIRC KTM wiring diagrams indicate the cable size the OEM look uses.

Vehicle Wiring Products and KojayCat are two UK sources of OEM connectors and cable.

[WesleyDRZ400]

Thanks for replys, basically i had the 660/640 rear rallye tanks In which I intended to fit but to do this you also need the rallye shock as it has a remote reservoir as standard shock reservoir hits left side tank and so does the airbox so you also need to fit the 660 airbox.

All I was waiting on was a 660 rallye subframe but no luck on searches....... So I built one.

Now I need to relocate the ecu, rectifier and solonode due to fitting the 660 airbox so I decided to bolt them down under rear mudguard on the tray.

Now I need to make the cables longer hence new wire with connectors. Current connectors had a loose wire which I now found.

However I have the neutral switch wire fault now so need to either replace this or bypass it

[WesleyDRZ400]

IMG_20200604_222303.jpg (129.74 KiB) Viewed 2789 times

[PHILinFRANCE]

Hi Wesley, long time no see , what you planning for the 640