Gear indicator on KTM 690 / HQV 701 models

Update:

With our CUMPAN add-on module, a fully functional gear indicator is now possible even on the older LC4 engines (2007–2013).

In this article, we want to talk about the compatibility of the CUMPAN gear indicator and show which models are supported.

In principle, the gear indicator works by having the CUMPAN interpret a voltage value. This voltage value has to be supplied by a gear position sensor that is already installed on the motorcycle. The CUMPAN therefore strictly depends on a factory-installed gear position sensor being present on the bike.

On older 690 models, a gear sensor is installed that has a 3-pin connector and only detects neutral as well as gears 2–3. This sensor provides information to the ECU, which adjusts the fuel injection when the motorcycle is in 2nd or 3rd gear. In theory, the CUMPAN can also display these signals, but in that case only gears 2–3 and neutral can be shown.

On the newer 690/701 models, there is a full gear position sensor that outputs voltage values for each individual gear. This allows the CUMPAN to display all gears and it only needs to be connected to the corresponding wire of the gear sensor for this purpose. In addition, it is recommended to calibrate the CUMPAN so that the exact voltage values can be assigned to the respective gears. These newer gear sensors have a 4-pin or 6-pin connector.

There are two ways to find out which gear sensor is installed on your motorcycle:

1. Via the part number or the connector

As already described, there are two different gear sensors on the earlier 690 models. The older version has a 3-pin (triangular) connector, the newer version a 4-pin (rectangular) one. So you simply need to locate the gear sensor on the engine housing and follow its cable to the connector. There you can identify the respective connector. The gear sensor is located on the left side of the engine housing, above the shift shaft. On the older models it is position no. 32 (3-pin connector) and on the newer models it is position no. 32 (4-pin connector).

The EURO 4/5 models (KTM 690 models from 2019 onwards | HUSQVARNA 701 models from 2017 onwards | GasGas 700 models all) also have a gear sensor that detects all gears. This sensor has a 6-pin connector – position no. 30. The CUMPAN gear indicator is fully compatible with this. As an alternative to the splice connector included in the kit, an optional inline adapter for the gear signal can be purchased.

The signal wire of the gear sensor is brown-green on all models (between ECU and connector). This is the wire that the CUMPAN must be connected to.

Important notes:

► The wire color between the gear sensor and the 6-pin connector described above is white.

On the opposite side of the connector, the wire color changes to brown-green.

► At the throttle body there is a flat, single-row connector that also has a brown-green wire. This is not the correct wire.
The correct connector with the corresponding wire is a 2-row connector and is, as described, located on the gear sensor harness.

► In the steering head area there may be another 6-pin connector depending on the model. This connector is also not the gear sensor connector you are looking for, and you will not find the brown-green wire there.

► With the gear sensor connector unplugged, the ignition must not be switched on. Otherwise the gear sensor loses its learned position and must be recalibrated by a qualified workshop. This fault can be recognized if the bike no longer shows neutral.

HUSQVARNA 701 (2018)

2. Via the engine number

The engine number is stamped on the left side of the housing and has the following format: x-xxx*xxxxx*

HUSQVARNA 701 (2018)

The number can be decoded as follows:

1st position: Year of manufacture (here: 2018)

2nd position: Engine type (here: 766)

There are 2 engine types on the older 690 models:

► 760 – model with ABS and a potentiometer gear sensor that can detect all gears, and

► 765 or 753 – models without ABS and a gear sensor that can only detect whether the gear is “neutral” or not

3rd position: Serial number (here: 54026)

The engine type 760 includes the following models:

  • KTM ► DUKE + DUKE R (2012–2015), 690 SMC-R (2014–2017), 690 Enduro (2014–2018)
  • HUSQVARNA ► 701 Supermoto + Enduro (only 2016)

In general, the information given here can be applied to all SMC-R, Supermoto or Enduro models from KTM, HUSQVARNA and GasGas (from 2022 onwards).

However, there may be differences between market-specific models (EU, US or AU models). The most important criterion, independent of model year, is to determine which gear sensor is installed. If it has a 4-pin or 6-pin connector, a full gear indicator with the CUMPAN is possible.

Related Posts