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Old 06-10-2013, 09:12 AM   #46
unaweep
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OK- I finished mounting the Squadron on my SE and went for a 300 mile gravel road test ride yesterday to see how it holds up. In a word- GREAT!!

Amazingly simple to install; CHEAP, CHEAP, CHEAP and pretty good looking. I'll post up pics tonight when I get home. Surely, some of you FFs can vastly improve on the simple design cross-country and I (mostly cross-country)worked up with just some junk lying around his garage.

The only thing I have not yet done is hook up power to it. I'm searching for the connector that would go from a stock KTM 500 wiring harness to plug into the squadron. Anyone have any recommendations?

Pics tonight!
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Old 06-10-2013, 10:52 AM   #47
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Originally Posted by unaweep View Post
OK- I finished mounting the Squadron on my SE and went for a 300 mile gravel road test ride yesterday to see how it holds up. In a word- GREAT!!

Amazingly simple to install; CHEAP, CHEAP, CHEAP and pretty good looking. I'll post up pics tonight when I get home. Surely, some of you FFs can vastly improve on the simple design cross-country and I (mostly cross-country)worked up with just some junk lying around his garage.

The only thing I have not yet done is hook up power to it. I'm searching for the connector that would go from a stock KTM 500 wiring harness to plug into the squadron. Anyone have any recommendations?

Pics tonight!
Thanks for the support. Is it the small red ktm connector? If you add a pic I can let you know if we have them.
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Old 06-10-2013, 06:41 PM   #48
unaweep
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Here's the final product:



I'm gonna post short messages because I seem to keep fucking up and deleting what I've worked on writing.
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Old 06-10-2013, 06:47 PM   #49
unaweep
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First, we pulled the stock head-light off. Junk.

I wanted to make it fit while keeping the original design/ positioning of the computer, etc.

So, cross-country and I dug around his garage and found this junk:



This is a piece of 1.5" by 1.5" aluminum angle. We used the fender screws to attach this to the top side of the bottom triple clamp. Before attaching it, we took a piece of flat-bar aluminum and screwed it to the inside of the angle leg that stands up. We also drilled a hole in the flat bar and tapped some threads into it. We left the hole in the angle piece unthreaded. That is why you see the screws on the face. It's holding the flat bar in place.
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Old 06-10-2013, 06:51 PM   #50
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Then, we dug up the following stuff in the bowels of cross-country's garage:



This is a piece used to rest the gas tank from an LC4 onto the frame. It's larger than a similarly shaped piece that you would use to secure a gas tank onto a small thumper.
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Old 06-10-2013, 06:56 PM   #51
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We also used this fender washer:



And this screw used to secure plastic on a KTM



These items were used to secure the top of the Squadron light to the existing plastic on the 950 SE that secured the OEM light. I took this piece of the OEM set-up, disconnected it from the top and bottom, and used the above to secure the light to the stock housing.



This is the stock housing to the light/computer holder/blinker mount. The above screw was a perfect fit. So, going from the black plastic, stock housing, I applied the circular rubber tank brace thing to the plastic housing. I put the light, with frame, over the circular spacer- cuz that's what it has become, then the fender washer and secured it with the screw, above.
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Old 06-10-2013, 07:06 PM   #52
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We did this to both sides and it was probably the most difficult part of the whole project, because you need to install each side, leaving little room to work.

Then, I drilled a hole in the bottom of the Squadron- actually, more like a slot.

I ran this screw:



Through the hole I drilled in the base of the Squadron and put this fitting



on the outside of the light so that it looks like this from the outside:



On the other side, I found a spring that I wrapped in electrical tape and ran the screw through to give some resistance



Ignore the two pieces- I cut it a bit too short at first.

Then ran the screw, with the spring on the back side of the light into the aluminum angle already mounted and threaded. I had an adjustable head light.
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Old 06-10-2013, 07:13 PM   #53
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The only thing I have not done is hook up the juice. I didn't want to damage the stock Squadron light's wiring- which looks like this:





And, this is the stock fitting from my 500 EXC that connects to the Squadron





So, that's all I need to do to get light. I rode 300 miles over 6.5 hours on gravel roads- speeds up to 110 mph- and it never moved.

Surely, you guys can do a better job than me.

I'm about 4 beers into this write-up, so if you have any questions, I'd be happy to answer them tomorrow.
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Old 06-10-2013, 07:44 PM   #54
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Thought I'd give a little more insight to how I used the spacer, washer and screw to attach the light to the stock housing.

So, we have the stock housing with this little piece extruding out:



So, I took the spacer and placed it over that little extrusion:



It fits loosely. Next, I took the stock number plate and headlight housing from the 500 and placed the fixture next to the spacer. The fisture has a hole in it to accommodate the rubber mounting straps.



Hard to see, I know. Then, put the fender washer over the fixture and screwed the screw in to secure it.

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Old 06-10-2013, 08:12 PM   #55
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Originally Posted by unaweep View Post
The only thing I have not yet done is hook up power to it. I'm searching for the connector that would go from a stock KTM 500 wiring harness to plug into the squadron. Anyone have any recommendations?
Pics tonight!
Hitachi/Sumitomo .110 connectors. Used on nearly every KTM headlight (2 pin version is also used for the front brake microswitch)

http://www.easternbeaver.com/Main/El...onnectors.html super useful site in Japan (fast shipping to US) but has a minimum order.

corsa-tecnic sells them too, they are in the US, will ship USPS 1st class and have no minimum I believe.

Somethings odd with their website certificate right now (pics aren't displaying):

http://www.corsa-technic.com/categor...category_id=53
the headlight harness side is A4AP: http://www.corsa-technic.com/item_images/A4AP.jpg
the wiring harness side is A4AS: http://www.corsa-technic.com/item_images/A4AS.jpg

if you order get a couple extra pins in case you break one
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Old 06-10-2013, 08:24 PM   #56
unaweep
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Quote:
Originally Posted by crazybrit View Post
Hitachi/Sumitomo .110 connectors. Used on nearly every KTM headlight (2 pin version is also used for the front brake microswitch)

http://www.easternbeaver.com/Main/El...onnectors.html super useful site in Japan (fast shipping to US) but has a minimum order.

corsa-tecnic sells them too, they are in the US, will ship USPS 1st class and have no minimum I believe.

Somethings odd with their website certificate right now (pics aren't displaying):

http://www.corsa-technic.com/categor...category_id=53
the headlight harness side is A4AP: http://www.corsa-technic.com/item_images/A4AP.jpg
the wiring harness side is A4AS: http://www.corsa-technic.com/item_images/A4AS.jpg

if you order get a couple extra pins in case you break one

Wow! What a great source. Thank you.
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Old 06-10-2013, 08:26 PM   #57
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Pic from the side?



Do you have any pics from the sides and sitting position? I think this mod is in my future... so sick of this stupid stock headlight!

Well done! Thanks for being willing to post the details.
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Old 06-10-2013, 08:35 PM   #58
unaweep
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Tomorrow I'll have pics. Didn't get it reassembled tonight. It's no different from stock from seated position or side view. Its probably smaller than stock at profile. There's NO gap,but it is certainly not waterproof by any means- which i believe is harmless for us.

Edit to add- I've tried to ride this bike stock and with convversion hid on a couple long late night off road rides. Either are useless and suck. Recently did some of the same rides with the squadrons on a smaller bike. "night and day" difference.

unaweep screwed with this post 06-10-2013 at 08:43 PM
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Old 06-11-2013, 08:52 AM   #59
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Nice job Unaweep! So how many beerhours were spent on this build?
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Old 06-11-2013, 09:04 AM   #60
unaweep
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Nice job Unaweep! So how many beerhours were spent on this build?
Including yours? I think I'm up to about 4 years.
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