Welcome to a tour through a typical HEX ezCAN PURE installation. Here, you will see what’s involved in a from-scratch installation of a HEX ezCAN PURE, its generic input harness, and typical accessories on a 2015 KTM 690 Enduro R.
If you would like to read detailed instructions on how to install a HEX ezCAN PURE and its generic input harness instead, click here.
If you would like to read instructions on how to install an optional plug-&-play input harness for your specific motorcycle, click here.
First, we had to remove components to access the input tap points we needed.
1. On our KTM, the seat, underseat battery cover, rear fender, right-side fairing panel, voltage regulator support bracket, and headlight mask had to be removed. Your needs may be different!
2. The negative (–) and positive (+) terminals were removed from the KTM’s battery.
When installing a HEX ezCAN PURE, we always recommend that you place the main body as close to the vehicle’s battery as practically possible.
Our experience has shown that this placement gives the best combination of input connector placement, battery cable slack, ease of access to the USB port and status LED, and protection from damage.
On our KTM, we found an ideal location for the HEX ezCAN PURE and its main fuse behind the battery (left).
All wiring runs you plan to use for the generic input harness must be carefully planned, and kept as simple as possible.
As a general rule, when it’s connected to the 6-pin JWPF connector on the HEX ezCAN PURE, the wiring of a generic input harness should ‘run’ in two directions:
TIP: Clothes-washing pegs (clothes pins) are ideal for temporarily holding wiring in place when planning the wiring runs!
On our KTM, with the HEX ezCAN PURE located behind the battery and the input harness connected to the HEX ezCAN PURE’s 6-pin JWPF plug, the wiring run for the input harness’ IGNITION, BRAKE, LEFT TURN and RIGHT TURN wires is planned (right).
The input harness’ IGNITION, BRAKE, LEFT TURN and RIGHT TURN wiring run lengths are finalized near the rear edge of the seat, and protective braiding is installed over the four wires.
The input harness’ HIGH BEAM and HORN wires are ‘doubled back’ in the direction of their tap points (left).
From the point they ‘double back’, the input harness’ HIGH BEAM and HORN wires are routed along existing wiring runs over the fuel tank, and along the right side of the engine airbox (right).
The HIGH BEAM and HORN wires follow existing wiring past the coolant reservoir (left).
The HIGH BEAM and HORN wires continue to follow existing wiring through the headstock splash panel (right).
The HIGH BEAM and HORN wires are routed to their tap points near the left switchgear wiring harness connector (left).
With the directions and lengths of the generic input harness’ wiring runs finalized and checked, the protective braiding and heat-shrink tubing were installed. The generic input harness was now ready for permanent installation (right).
With our KTM’s input harness connected to the HEX ezCAN PURE, the input harness was secured along existing wiring runs using the cable ties included in the HEX ezCAN installation kit (left).
Note the amount of slack given at the ‘double back’ point. This was done to prevent strain on the input harness wires.
As is usual with all well-done electronic installations, care was taken to route the battery cabling safely and securely, in a way that did not allow it to chafe or pinch, before the HEX ezCAN’s battery cables were secured to the battery terminals.
Where needed, wiring was secured to frame tubes and other components, using the cable ties supplied with the HEX ezCAN PURE installation kit.
On our KTM, power output connections for the front spotlights (in this case, the red and blue power circuits) were made to HEX ezCAN Extension Kit cables. In turn, these were routed around the engine ECU and forward to the headstock (left).
The power output connection for the auxiliary horn (in this case, the yellow power circuit) was made to a two-core cable routed along the right side of the engine airbox.
The power output connections for the spotlights and horn were routed forward along the bike’s main wiring harness (right).
The power output connections for the spotlights, and the front portion of the input harness, continue forward to the frame headstock (left).
The power output connection for the accessory horn is routed downward to where the horn is installed on the right front engine mount (right).
To maximize their usable light, the spotlights were installed high on the handlebars (left).
The spotlight power connectors are routed backward through the headstock splash panel, toward the female terminals of the HEX ezCAN extension cables.
To avoid conflict with the bike’s main wiring harness, the spotlight power cables do not share precisely the same routing as the factory wiring. Note the amount of slack given to the spotlight power cabling: this allows free movement with no conflict at full steering lock, in both directions (right).
You will now be redirected to our primary website to view our Privacy Policy
You will now be redirected to our primary website to view our Legal Information
You will now be redirected to our primary website to view our Legal Information