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Old 03-21-2010, 08:25 PM   #1
Hodakaguy OP
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Location: Eastern WA State
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Let there be Light! - 8" Trailtech Headlight/KTM 530 Install

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 ...Thanks Doug and Lee! Now to get it installed.......




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.




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.




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.




Light is on the bike 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.






Top Shot




Front Shot







Hodakaguy
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Old 03-21-2010, 08:35 PM   #2
RedlegDaddy
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Nicely done, looks awesome! I think I will be doing the same thing to my 690 R if I end up keeping it.
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Old 03-21-2010, 08:36 PM   #3
uvawiseiochemist
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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.
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Old 03-22-2010, 03:01 AM   #4
LukasM
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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
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Old 03-22-2010, 03:19 AM   #5
LC8TY
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Awesome

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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Old 03-22-2010, 04:08 AM   #6
unlawfulsm
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Quote:
Originally Posted by LC8TY
Awesome

Do you know what the threads welded to the upper mounts are for?
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.


Crappy pic, but you get the idea


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Old 03-22-2010, 05:34 AM   #7
LC8TY
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Thanks unlawfulsm

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

looking good
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Old 03-22-2010, 05:35 AM   #8
Hodakaguy OP
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Quote:
Originally Posted by LukasM
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
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
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Old 09-29-2010, 08:48 PM   #9
brettparkhurst
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How is the light holding up?

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?
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Old 10-06-2011, 05:48 AM   #10
arenfro425
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KTM headlight

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,
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Old 10-06-2011, 07:49 AM   #11
Hodakaguy OP
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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.



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