Let there be Light! - 8" Trailtech Headlight/KTM 530 Install

Discussion in 'Thumpers' started by Hodakaguy, Mar 21, 2010.

  1. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,457
    Location:
    Eastern WA State
    Last year when we did our big desert trip we ended up riding a little at night a couple times, it was then that I found out what a piece of junk the stock headlight is on my 530exc, it was absolutely pathetic....almost worthless! Fast forward a year and we are getting ready for another desert adventure this summer...and the stock headlight has to go!

    I looked at the Trailtech X2 HID Light but I personally don't care for the over under looks of that unit, I had the Trailtech 8" Race Light on my XRR and loved it so I decided to go that route again on the 530.

    Craig2211 and I ordered the Race Lights from Dual Sport Armory and they showed up a couple days ago :clap ...Thanks Doug and Lee! Now to get it installed.......


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    One last shot of the bike with the stock headlight on it. This was taken last Friday, my friend Travis just picked up a 530 of his own and we were out putting some miles on it. :thumb


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    Under the stock headlight lives a BUNCH of wiring. In this picture I've already removed the factory connectors from their metal holder and started to straiten out the wiring as much as possible. The Race Light interfered with the wiring in it's stock location so re-arranging the wiring is a must. KTM uses HUGE connectors everywhere, I started cutting and trimming wherever possible to reduce the bulk of the wiring. I replaced several of the factory connectors with RC aircraft bullet connectors, they can carry high amp loads, are super reliable and take up a lot less space.


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    Well not perfect but it will get the job done, and it's a lot cleaner than it was. Once the light is in place it looks great. I used a piece of old tube to enclose the bulk of the wiring at the bottom, I punched a row of 1/2" holes all along the bottom of the tube in case water gets in. I also packed the remaining connectors full of Dielectric grease as a further waterproofing measure.


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    Light is on the bike :clap No more riding in the dark for me! The back of the light comes in a chrome finish from Trailtech, I removed the lens and painted the back a high temp flat black to make it blend in better.


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    Top Shot


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    Front Shot


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    Hodakaguy
    #1
  2. RedlegDaddy

    RedlegDaddy Been here awhile

    Joined:
    Feb 16, 2007
    Oddometer:
    616
    Location:
    SE Arizona
    Nicely done, looks awesome! I think I will be doing the same thing to my 690 R if I end up keeping it.
    #2
  3. uvawiseiochemist

    uvawiseiochemist Adventurer

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    Jul 17, 2009
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    Location:
    Southwest Virginia, deep in the Appalachian Mtns.
    I love these lights. I would love to see how these things work in the dark, and plan to add a setup like it to my bike eventually. The install looks very nice.
    #3
  4. LukasM

    LukasM Long timer

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    On a RTW ride - currently touring the U.S.
    Excellent work as usual Tom!

    I really like how you cleaned up the wiring. Do you have a link to show the bullet connectors you used?

    Thanks,
    Lukas
    #4
  5. LC8TY

    LC8TY must......find........fuel

    Joined:
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    Awesome :thumb

    I realy like the Baja race bike look, might do the same thing with my new 530, if thats OK with you mate?

    Do you know what the threads welded to the upper mounts are for?
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    #5
  6. Bearded Hooligan

    Bearded Hooligan Moto Addict

    Joined:
    Mar 30, 2004
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    903
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    Flat, Hot & Humid South GA
    Its for a ballast plate for when fitting an HID light. It is an extra cost, but I bought one to mount my GPS to.
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    Crappy pic, but you get the idea
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    #6
  7. LC8TY

    LC8TY must......find........fuel

    Joined:
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    Location:
    Carnarvon, Australia
    Thanks unlawfulsm

    Thats exactly what I was thinking, I have the same GPS and mount as you.

    looking good :thumb
    #7
  8. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Eastern WA State
    Thanks, here is a write up on the connectors CLICK HERE, that was on my old XRR and this time I used the next size up connector but it's the same otherwise.

    Hodakaguy
    #8
  9. brettparkhurst

    brettparkhurst n00b

    Joined:
    Mar 24, 2009
    Oddometer:
    1
    I am really considering putting this light on my 09' 450 EXC. Very cool! I was wondering how it is holding up? I ride a lot of rocky mountain trails and catch some air sometimes. Do you think this light would hold up to the abuse?
    #9
  10. arenfro425

    arenfro425 Adventurer

    Joined:
    Feb 15, 2010
    Oddometer:
    20
    Man I love what you have done with the headlight project. Is that the HID or Halegen light? The Trailtech makes the other racelight with the 3 lights, any thoughts on that one? I installed a electrosport 3 ph stator and next is a worthy light!

    Cheers,
    arenfro425
    #10
  11. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,457
    Location:
    Eastern WA State
    The lights been holding up great, I've ridden thousands of miles of desert and lots of single track without a single issue. I'm running the halogen light, with a HID light it's best to let them cool a bit after turning them off before you re-fire them again...I'm always starting and stopping while on the trail so figured the Halogen would work best for me (I'm sure the HID unit would hold up for a long time as well though).

    Here's a video of the race light getting a work out recently...gets REALLY rocky/rough towards the end of the video.

    <iframe width="640" height="360" src="http://www.youtube.com/embed/Q564_TYjHdU" frameborder="0" allowfullscreen></iframe>

    Hodakaguy
    #11