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Old 04-06-2012, 07:41 PM   #241
Yellow Pig
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Got one of the first dimmers in!

Here is my installation and a few comments.

The BD dimmer box is a bit larger than I would have liked.
It comes in at 2 5/8 x 2 5/8 x 1.5.

The container is very sturdy and appears to be waterproof.










It is however smaller than the competition:


These two do appear to use the same hardware and key-fob switch, but are packaged in different containers.



The two wireless key fob dimmers a much larger than this electronic dimmer which uses a special power on/off sequenced to set the dimmed light level.



I installed my dimmer on a 2010 KTM XC-W that has a Squadron LED light and a SicAss plug and play dual sport kit installed.

I installed a 4 pin connector on the KTM to facilitate connecting the Dimmer and the Squadron LED.



In the above picture the wiring goes as follows:
Brown = Ground
White = Marker light
Green = Low beam
Yellow = High beam

Here is the SicAss Hi/Lo switch:



And the KTM OEM lights On/Off switch:



I followed the provided wiring diagram and connected:

Ground --> LED - (Black)
Marker Light --> LED + (Red)
High beam --> High beam by pass wire (Yellow)

Note: you cannot connect the LED + to the Low beam because that wire needs a constant power-source. With the Hi/Lo switch once you flick on the High beam it cuts power to the Low beam......thus the connection to the marker light which provides a constant power source, even when the high beam is engaged.




Here are the Squadron LED and the Dimmer all set up for installation on the bike:




Baja Designs provides some industrial Velcro for the installation of the dimmer box, but I wanted a more solid solution and fabricated a Kydex shelf that sits above the Squadron light on which the dimmer is securely zip tied:






The BD Dimmer is paired up to a unique serial number key fob that can be used to adjust the power level of the LED light:


This matched key fob provides approximately 18 levels of adjustment in intensity of light that goes from 0 --> 100% intensity.

Doing some initial testing I found that the best setting for low beam is around the 30% mark. Anything above that is too bright for head on traffic, particularly at night.


Here is the Squadron on the lowest dimmer setting:


Here it is on full eyeball melt:



The key fob works great and the dimmer module remembers the last setting so all you need to do is find the low beam setting you like and forget about the key fob. Despite this there is something psychological I do not like about having a separate key fob. I find the dimmer with the built in dimming sequence to be more reassuring, but I understand it is a mere mental trick I need to overcome.
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Yellow Pig screwed with this post 04-06-2012 at 08:26 PM
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Old 04-06-2012, 08:03 PM   #242
Yellow Pig
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Here are some crappy night shots of the light/dimmer in action. The point and shoot camera I used certainly does not do justice to the light quality.


30% Power:



100% Power:



Squadron at full power:






There is more light spread than the pictures show, but the cheapo camera I have focused on the hot spot of the beam.
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Yellow Pig screwed with this post 04-06-2012 at 08:19 PM
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Old 04-06-2012, 09:28 PM   #243
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Quote:
Originally Posted by Baja Designs View Post

Here you go guys.
Thanks,
Gordon Allen
Gordon, on the diagram, the Yellow wire goes to a device labeled "Headlight", not "Headlight Switch", so which is it:

Postive (+12v) on Yellow to toggle on full power?

or

Ground (-) the Yellow for full power?

The diagram vs the text provided is not clear enough, or maybe I'm tired after a long day... Thanks.
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Old 04-06-2012, 09:52 PM   #244
Yellow Pig
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What the diagram shows is the use of an Auxiliary LED in conjunction w/ a stock headlight.

If you are only using an LED Headlight the Yellow gets connected to the high beam switch, the Black to the Battery - & the Red to the Battery + or any constant power source.

That works in this configuration:



but not this one:



Clear as mud!
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Old 04-07-2012, 08:39 AM   #245
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You can connect the red lead to the low beam wire, the yellow lead to the high beam wire and use a 5 amp diode between the low and high beam leads if you want to power the dimmer from the stock headlight wiring. (Tip: if the high beam doesnt work then the diode is connected backward.)

I was hoping to see this built in to the dimmer but its not hard to do.
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Old 04-07-2012, 09:54 AM   #246
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Quote:
Originally Posted by MJS View Post
You can connect the red lead to the low beam wire, the yellow lead to the high beam wire and use a 5 amp diode between the low and high beam leads if you want to power the dimmer from the stock headlight wiring. (Tip: if the high beam doesnt work then the diode is connected backward.)

I was hoping to see this built in to the dimmer but its not hard to do.
Thanks YP and MJS, so from that I gather apply positive 12V to the yellow while the red has solid power for full, whatever config is done. i.e. active high.
I understand about the diode for running the unit off just the Hi/Lo headlight leads.

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Old 04-07-2012, 01:55 PM   #247
Yellow Pig
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Think of the yellow wire as a relay that triggers the High Beam
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Old 04-09-2012, 08:46 AM   #248
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Thanks Guy's for the all the help, I will make some revisions to the instructions to make them more clear. Also thanks for all the great pictures Dan. Hope everyone had a great Easter.

Thanks,

Gordon BD
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Old 04-09-2012, 09:49 AM   #249
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What about making this light to work for those of us with low output AC dirt bikes, like the KDX 200/220?
Even though Kawasaki ceased production of these models a few years ago, they were, arguably, the most prolific dirt bike ever produced, and as such, there are many thousands of these bikes still in use today.

This is a huge market that would gladly pay for a chance to update from the feeble, stock 35 watt headlight bulb these bikes were originally equipped with.

ktm950se
Any chance this will happen?

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Old 04-11-2012, 07:48 AM   #250
heetseeker
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Index

Great post Yellow Pig...

I put that in the thread index under 'Headlight'

http://advrider.com/forums/showpost....35&postcount=1
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Old 04-11-2012, 08:22 AM   #251
Baja Designs
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Quote:
Originally Posted by ktm950se View Post
Any chance this will happen?

ktm950se


Yes, if you do a full D/C conversion on those bikes than you will be able to run the Squadron, but you will need D/C power. Let me know if you have any questions.

Thanks,

Gordon BD
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Old 04-12-2012, 04:26 AM   #252
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OK, great!
Can you provide me with a link to where this D/C conversion kit is on your website?

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Old 04-12-2012, 09:04 AM   #253
Baja Designs
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OK, great!
Can you provide me with a link to where this D/C conversion kit is on your website?

ktm950se
Hey,

These will be all the parts you will need in order to run a better light, but keep in mind if you are using it for a dual sport bike than you will still have to run a 35w bulb for the best efficiency. If you are using it for a race light you can run the Squadron and a few other lights. If you have any questions just let me know.

Thanks,

Gordon BD

12-6002 - KDX Stator rewind - goes from 40-80watts

12-2004 - Regulator/ Rectifier DC wired

12-0315 - Nicad Battery pack
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Old 04-12-2012, 10:22 AM   #254
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Super, thanks!!!

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Old 04-12-2012, 10:25 AM   #255
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No worries
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