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Old 03-30-2013, 07:14 PM   #226
rtwpaul OP
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Originally Posted by chasbo View Post
Awesome! Now the real fun starts....at least it is clean Paul...
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Old 03-30-2013, 07:43 PM   #227
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Originally Posted by rtwpaul View Post
i'll do the clean up first, no better way to get to know your bike, all comes in handy out in the middle of nowhere...just adding a new harness is the easy way out and doesn't help me gaining knowledge on my first piece of orange...

then and only then if i still have problems i will look into a new harness...wiring isn't that bad if you look at it in small sections, and personally i don't like these type of connectors, i will probably do a swap to deutsch connectors, a lot easier to work with
I gotta agree, I was surprised when I first dug into the electrics on the KTM. Compared to the rest of the bike it seemed cheaply done.

Where do you source those connectors from?
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Old 03-30-2013, 08:23 PM   #228
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Where do you source those connectors from?
when i was a parts unlimited/ drag specialties dealer i got them from there, very easy to use and they come in multiple configurations (Available in 2, 3, 4, 6, 8, and 12 cavity arrangements) click this link deutsch connectors and find someone near you or even your local good quality electrical store is probably a good choice or of course there always ebay - link just make sure you get the correct male and female connectors, and radio shack used to sell the crimping too for less than $10

once you use them you might not use anything else they are so easy
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Old 03-30-2013, 10:43 PM   #229
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just posted a bunch of stuff for sale in the flea market that i think some of you would be interested in, check them out

here - loads of books

and here - loads of maps

and here small tools




.

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Old 03-31-2013, 12:28 AM   #230
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Duetch connectors are awesome.

Fyi, they are oem on Cat and Harley. I bought a 400 piece kit on ebay for a couple hundred.
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Old 03-31-2013, 07:51 AM   #231
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Originally Posted by wrk2surf View Post

If I was riding around the world I would buy a new harness and some extra connectors and pins

With your level of skill and experience, I think I'd opt for making my own harness and improving on the KTM factory stuff.
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Old 03-31-2013, 09:08 AM   #232
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Originally Posted by Kawidad View Post
With your level of skill and experience, I think I'd opt for making my own harness and improving on the KTM factory stuff.
i'll sure give it a dam good try, thanks for the envouragement
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Old 03-31-2013, 01:30 PM   #233
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Originally Posted by rtwpaul View Post
i'll do the clean up first, no better way to get to know your bike, all comes in handy out in the middle of nowhere...just adding a new harness is the easy way out and doesn't help me gaining knowledge on my first piece of orange...

then and only then if i still have problems i will look into a new harness...wiring isn't that bad if you look at it in small sections, and personally i don't like these type of connectors, i will probably do a swap to deutsch connectors, a lot easier to work with
I agree Paul ... IMO, that wiring job is not that bad ... and it's been working. I've seen MUCH MUCH worse.

But it's obvious your bike has more than 500 miles on her. We see this same "miracle low mileage" thing on DR650's too. On our bike, a 7th grader with pliers can pull the speedo cable in 5 minutes.
"What a World, What a World!"
But, IMO, your bike shows care. Somebody looked after it.
Good luck with the cooler and adding capacity!
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Old 04-03-2013, 08:41 AM   #234
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I'd really like to see what you're going to do with the wiring harness. You should see the rats nest of zip ties, connectors, electrical tape and mismatched cables that is my harness. There could really be a lot of simplification on my 02 adventure there are quite a few connectors that aren't used and cables that are run to nothing. I think the harness is used on a few different bikes.
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Old 04-03-2013, 06:26 PM   #235
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Another 625 owner checking in. This thread is turning out to be a great resource for the 625.

Mine's an 03 w/ Excel rims + cush, LC4 tank/seat, Pastrana bend bars, center + sidestand, pro moto rack. Next phase is HB racks w/ Wolfman softbags, tool tube, LC4 rear fender & a lightbar mounted to the rack.

Interested in seeing your wiring mods and how you address the oil issue. How much more oil are you adding and what do you anticipate the oil life to be?

One common problem I don't think has come up yet is the counter shaft seal - many of them leak.



My contribution to 625 porn:

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Old 04-03-2013, 07:29 PM   #236
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Originally Posted by rtwpaul View Post
so once that was done i took off the headlight....holy Fkg ĥĬŧē

.
I won't show you under the dash of my 640 then That looks like childs play compared with mine, there are a few more wires on the E from stock, it was a mess from new & I've crammed in a few extra bits since then. I have only had a couple of issues in there though, both with wires breaking off the back of terminals in the stock plugs & easily found & fixed. The only time the 640 has had to take a tow was when a wire rubbed through against another just out of the igniter box plug, took us a few hrs to find that one.

Really interested to see what you do there, when I get around to making up my new light setup I'd like to tidy up that wiring also.

Re: Oil. Whatever. I've just run a decent full synth or semi synth motorcycle specific 10-50 or 20-50. Motul & Motorex in the past, Rock Oil gold full synth for the last 50K km or so cos it's good value at the local dealer. The bike doesn't get used in stupid-hot conditions very often but the motor did do 95K km before needing a rebuild (apart from the normal cam bearings & starter clutch at 50K km).

Cheers
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Old 04-03-2013, 07:49 PM   #237
rtwpaul OP
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Originally Posted by Johnny Drunkard View Post
Another 625 owner checking in. This thread is turning out to be a great resource for the 625.

Mine's an 03 w/ Excel rims + cush, LC4 tank/seat, Pastrana bend bars, center + sidestand, pro moto rack. Next phase is HB racks w/ Wolfman softbags, tool tube, LC4 rear fender & a lightbar mounted to the rack.

Interested in seeing your wiring mods and how you address the oil issue. How much more oil are you adding and what do you anticipate the oil life to be?

One common problem I don't think has come up yet is the counter shaft seal - many of them leak.
got a little sidetracked on the project, had some major truck issues that have taken precedence, promise i'll be back on this very soon...

the SXC holds 1.6, the 640A holds 2.1-2.2 so we are only really talking about half a liter to make them the same, by doing this i figure it should take oil changes from around 1500 to 3000 miles +/-

found a little time this afternoon, i had the thing in pieces today but first i did a quick mock up...



then it all came apart ready for some wiring correction



and i found out why the mileage was so low (maybe) missing a back up battery in the speedo for the 'memory'



seeing that i was a little pissed and i decided to work on the front end and leave the electrics for later

i had spoken with Craig at lexington motorsports most of you might know them as KTM parts house i had already contacted another GPR dealer about a steering dampner and was told they don't make one for the SXC! i specifically wanted an under bar mount and didn't like the gold Scotts version overbar...Craig called his inside source at KTM and they came up with a combination of parts so i could make this work...this is what you need if you didn't know already like me as this is my first orange bike



so i took the front end apart and found loads of grease so maybe my bike was built on a wednesday but wired on a friday ...but i still regreased the bearing and they were in good shape and so were the races




the new mount and stabilizer adds 2 lb 10 oz





add some bars - renthal RC high bend 922's



and some dual compound grips - 63002021200, need to find my safety wire and wire them on as well...later




so slap it all together, the bars that is



still not sure if i like the KTM speedo set up, really only need speed,distance and a couple of idiot lights...any suggestions, links?

OK, gotta get back to my truck
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Old 04-03-2013, 10:00 PM   #238
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Originally Posted by rtwpaul View Post
the SXC holds 1.6, the 640A holds 2.1-2.2 so we are only really talking about half a liter to make them the same, by doing this i figure it should take oil changes from around 1500 to 3000 miles +/-
The math isn't working out here. Boosting capacity by 25% doesn't double the number of miles between changes. It actually works the opposite way. The oil will be fresher and cleaner on average if you change 1 liter twice instead of 2 liters once for the same number of miles.

I am a fan of greater oil capacity but if supply is your concern you will be better off with a container of fresh oil in in your saddle bags than the same amount added to your system. Changing smaller capacity oil more frequently is more work but better for the engine.

If your concern is heat then more capacity and a cooler is the way to go.

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Old 04-03-2013, 10:42 PM   #239
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i get where you are coming from...hence the +/-...what you have to keep in mind here is where i am going, this isn't a trip to colorado, or 3 days in death valley or western TAT etc...

sure where and when possible i will do oil changes at around 2000 miles (with my additional oil capacity) but times i will have to stretch it out to 3000+, oil is cheap insurance, agreed

its very easy to say change your oil every 1000 - 1500 miles...but here's something for you to ponder where i will be getting my oil from, at times it won't be as easy as you think, hence my question earlier in this thread about oil choices in good times and bad

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Old 04-04-2013, 03:38 AM   #240
juames
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That is a sweet looking stabilizer setup! Wonder if it would work on my 640adv?

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