2012 ktm 500 exc?

Discussion in 'Thumpers' started by Visigothic, Apr 27, 2011.

  1. SoilSampleDave

    SoilSampleDave Dr. Zaius was right!

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    I'm only 6' tall, but I am really wanting to be able to come up with a standing position where I am able to lean forward enough to really be in a neutral position and not using a lot of energy. I have only been able to pull this off once before, on a DRZ where I flipped the offset bar mounts on the aftermarket clamp to a forward position. It was a little awkward while seated, but I could ride standing up seemingly endlessly with little effort. A little lightbulb went off over my head when I tried that, and have been wanting to re-create it ever since. I am going to try swapping to my favorite tall bars (Pastrana Freestyle bend) and see if that helps. The problem is that as you go up with risers, you also go back. From another post on here, I am also going to try the Pivot Pegz, which let you move the pegs down 12mm, and back 5mm. That might do the trick as well. I think this bike is a keeper, so I figure why not throw the checkbook at it! :evil
  2. SoilSampleDave

    SoilSampleDave Dr. Zaius was right!

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  3. J.Johnson

    J.Johnson Adventurer

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    [​IMG][​IMG][​IMG][​IMG][​IMG]
    Installed HDB hand guards, mirrors, turn signals. Baja Designs Squadron light. Scott's stabilizer. Billet radiator guards. All on my buddy's 2013 500 exc.


    Sent with mind control...
  4. SoilSampleDave

    SoilSampleDave Dr. Zaius was right!

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    I wish you would do that to my EXC!
    Sweet! :clap
  5. kbear

    kbear Mudbiker

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    I forgot to note that I have a heavier rear spring installed as well. I weigh in at 240#, so when the sag is set for my weight, it's another reason the +1 was too tall. I bought the foam and cover both times, and installed them myself. Wanna buy the +1? :wink: Never mind I sold it today....
  6. advdoctor

    advdoctor n00b

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    Did it require modding the factory lights to fit into the top clamp. Why did you choose to retain two in the computer protector rather then move them all down into the clamp?:huh
  7. bill1960

    bill1960 Been here awhile

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    I bought the baja designs keyed switch with my HDB setup.

    Its not plugnplay as far as I can tell.

    Whats the usual way to wire it into the 500 XCW ?
  8. Lulu7404

    Lulu7404 Been here awhile

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    Hey Dave. I have a seat concepts tall foam and cover. Like new condition. Bundy offered to buy the foam back from me and I just never sent it back. If you are interested, i posted some pictures of it earlier in this thread, just search by my handle. Shoot me a pm. $100 shipped and its yours. At 5'10", 30" inseam, it was just too tall for me. The standard foam is perfect for me.

    Brad
  9. J.Johnson

    J.Johnson Adventurer

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    That is how my buddy wanted it. Did not have to mod lights. Just drill out the clamp to the right size hole.


    Sent with mind control...
  10. J.Johnson

    J.Johnson Adventurer

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    You can contact Baja Designs. They are usually pretty helpful on the phone. Ck Thier website it might have something.


    Sent with mind control...
  11. Nomad

    Nomad High Speed Low Drag

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    I'm working on getting it wired in too but on my EXC. I havent talked to BD yet but I know if you send Paul at HDB an email, he could probably walk you through it. He's got the BD ignition switch wired into his XCW.
  12. theantipaul

    theantipaul Reforming Neandertal

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    Hey guys, I have 2 emails asking about this and this is what I sent off yesterday,

    I have the BD switch on my bike, but being an XCW I had to wire it in.

    The BD switch has 4 wires and 2 circuits, red and black are for the power circuit, red is typically the power from your battery and black is the switched power out of the switch. When the key is off, that circuit is open and no power flows. Turn to on and the battery powers up lights, etc.

    The other side of the switch is green and black w/white stripe wires, this is the kill circuit, typically the green is ground and the black w/white stripe is from your ignition, when the key is off this circuit is closed and the kill wire from your ignition is grounded so that the bike won't start. Turn it to on and the circuit is opened and the ignition is no longer grounded and the bike can start.

    Let me know if that helps and what you're trying to do and what bike you're dealing with.

    I'm not sure if Chad is a member here, but he's dealing with the same issue and he sent me a few photo's, from what I can tell from the KTM schematic, looks like 4 wires go into the KTM ignition switch, red and white w/orange stripe, these would be your power in and power out. Then there are black and blue wires, these should be kill.

    If I could get one of you EXC guys to check if the white w/orange stripe wire has 12v to it with the switch off, and then red and white w/orange stripe having 12v when the switch is on, that part would be solved, same with the black and blue, with an Ohm meter check continuity with ground, then we'll know which is ground and kill.

    My guess would be for the KTM switch is those are the 2 circuits,

    KTM----BD
    red----red
    white w/orange stripe----black
    black----green
    blue----black w/white stripe

    Now here's the confusing part, BD has wired in a 4 contact connector with only 2 wires, the kill circuit coming out, the black wire coming out is the green wire on the BD switch and the blue wire is the black w/white stripe, just like the KTM harness.

    I rewired the connector, so I didn't have to worry about all the rest.

    Let me know if any of this makes any sense the way I've explained it.
  13. theantipaul

    theantipaul Reforming Neandertal

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    Using my poor man's scanner,

    [​IMG]
  14. Nomad

    Nomad High Speed Low Drag

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    oh hey Paul, not sure if it makes a difference but theres only 3 wires coming from the bike. 2 white/orange and 1 red.

    [​IMG]

    in the stock plug you can see the red goes to orange and the 2 white/orange go to green.

    [​IMG]

    I'm gonna try and pick up a multimeter today. What I tried doing is connecting both white/orange to black and red to blue and vise versa but both ways causes the switch to work in reverse. Obviously I'm no electrician.
  15. Nomad

    Nomad High Speed Low Drag

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    here's a picture of the BD plug that needs to be wired in.

    [​IMG]
  16. theantipaul

    theantipaul Reforming Neandertal

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    The blue and black on the pigtail on the BD switch are for the kill/off circuit, so when you turn the switch off it closes the contact and from what I can tell the red and white w/orange are power out and power in, so when you turn the switch to off you're powering up the bike, which is what sounds like is happening.

    What are the blue and green on the KTM plug going to. They should be green=ground and blue=kill. Please check that.

    The BD switch has a 4 connector plug and the pigtail coming out is just the kill side, the other 2 that are not wired into the female side of the connector are for the power/on side of the switch, that's where the red and white w/stripe should be wired. When I wired mine in I added the wires into the connector, but I had all the parts because those are the connectors I wire my bike up with.

    Hope that makes sense.
  17. Nomad

    Nomad High Speed Low Drag

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    ok now I'm starting to get the big picture.
    do you mean the blue and white/red wire on the KTM plug? from what you said the orange and green are what I'm guessing are the power in and power out but the other two don't go to anything. just like on the BD switch there are 4 wires but on the BD pigtail there are only 2.

    Here's a picture of the switch side of the KTM plug.

    [​IMG]
  18. theantipaul

    theantipaul Reforming Neandertal

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    Chad with that pic could you check the continuity between the wires and the on/off position of the switch, then I could tell you how to wire it up.

    With the switch off are the green and blue connected and in the on are the orange and white w/red stripe connected? The red and the white w/orange stripe are on either side of the switch on the schematic are they on the bike side of the plug?

    Don't wire green in yet till we know where it goes, my guess is it's ground and you'll pop a fuse. What wires on the other side of the plug correspond to the colors on the switch side of the plug.

    Orange = ?
    White w/red stripe = ?
    Blue =?
    Green =?
  19. Nomad

    Nomad High Speed Low Drag

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    orange > red
    white/red >just ends in plug under green wire
    blue > just ends in plug under orange wire
    green > white/orange

    I picked up a multimeter but I'll have to check the wires in the a.m. when I get off work.
  20. bill1960

    bill1960 Been here awhile

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    Turns out the switch was pretty much plugnplay for the 500 XCW.

    It comes with a splice connector which you splice across the two wires coming from the kill button

    [​IMG]


    [​IMG]


    [​IMG]

    A small mounting bracket is included but I installed mine in the HDB topclamp which had a hole machined for that purpose

    [​IMG]

    The result is the motor will still turn over with the starter, but wont fire with the BD switch in the off position.
    On the XCW, lights etc will only work with the motor running.
    I guess you'd need to wire in the two other contacts of the BD switch to power up lights/etc with motor off.