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Old 08-02-2010, 10:50 AM   #1
67L48 OP
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Joined: Aug 2008
Location: Fort Collins, CO
Oddometer: 46
Headlight Wiring ?: 2004 KTM 450 EXC

2004 450 EXC

Headlight is all stock and I do have a wiring diagram.

I am trying to go from the stock switch to an aftermarket DS master switch.

Stock bulb has 3 prongs for ground, low and high. However, KTM factory wiring only uses the ground and low. That much I know.

The stock harness at the bulb has two wires: white and brown. I believe that brown is the ground and white is low beam.

The white wire goes into the factory light switch next to the digital meter. A yellow wire leaves the switch and goes into the factory wiring "path." I thing the yellow wire goes to the stator (generator).

The aftermarket switch has 3 wires that it calls Headlight Main (black), Low beam (white), and High beam (blue).

So, how do I connect it all together?

Here's my guess:
Connect the black "Headlight Main" to the factory yellow wire on the "battery side" of the factory headlight switch.
Connect the white Low Beam wire to the lightbulb prong where the factory white wire was connected.
Connect the blue High Beam wire to the lightbulb prong that was previously bare/open.
Leave the brown factory ground wire connected as is.

Is that correct? Or should I be connecting the black "Headlight Main" directly to the battery? Something else?
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Old 08-02-2010, 12:40 PM   #2
Tail Gunner
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Joined: Apr 2007
Location: The Sunshine State - Kirkland, WA
Oddometer: 1,610
Your guess is right. The headlight is AC and should not connect to the battery (which is DC). It gets its power from the AC stator. This link might help you understand the options with stators
http://ktmtalk.com/index.php?showtopic=395998



Here's my guess:
Connect the black "Headlight Main" to the factory yellow wire on the "battery side" of the factory headlight switch.
Connect the white Low Beam wire to the lightbulb prong where the factory white wire was connected.
Connect the blue High Beam wire to the lightbulb prong that was previously bare/open.
Leave the brown factory ground wire connected as is.
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