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

Nice!

You must be planning some serious backcountry miles with the light and the supertanker. Tank looks good too, did it come with the heat shield tape? My tape is starting to peel after two seasons.

Have a good one

griz

Nice job, it looks good on the 530.

I love my Trail Tech when the sun goes down.

griz901 wrote:

Nice!

You must be planning some serious backcountry miles with the light and the supertanker. Tank looks good too, did it come with the heat shield tape? My tape is starting to peel after two seasons.

Have a good one

griz

Yep we have a epic ride planned for this summer...1800 miles of fun! Look for a sweet ride report later this summer

I installed the heat tape when I purchased the tank, I have some pictures of the install on the heat tape...I'll dig them up and post them here.

Hodakaguy

Very cool! Good job on cleaning up all those wires. I believe my next project will be a new HID light set up. I like those 8" round ones. They are sweeeeet!

^ +1 That cleanup job on the wiring is awesome!

griz901 wrote:

Nice!

You must be planning some serious backcountry miles with the light and the supertanker. Tank looks good too, did it come with the heat shield tape? My tape is starting to peel after two seasons.

Have a good one

griz

Here's a shot of the tank after I installed the heat shield. I ordered it in a large sheet from a automotive performance shop. It took a good hr or two and a couple ice teas to get it installed.



Hodakaguy

Yeppers, that looks familiar! I used the tape version but its begun to peel here and there. I might have consumed a few beers that night too. I figured it wasn't a critical application, so I could splurge a little...

(End hijack )

headlight and wiring very nice addition. 3m makes some heat tape that comes in different widths that i have used on my snowmobile, an it seems to really stick good. so far i haven't had any come off.

Bookmarked, thank you very much. We did more than a few Walker Valley night rides last winter and you are of course correct: the stock lights are so someone can see you, not necessarily so you can see anything else, though. We messed around with head lamps and will continue to do so, but I want a new light.

Am I correct in understanding that it is not DOT approved, and if you want to make it so, then you must buy a different bulb that has a high/low beam?

I'm suprised it doesn't come with a cage.

T.Low wrote:

Bookmarked, thank you very much. We did more than a few Walker Valley night rides last winter and you are of course correct: the stock lights are so someone can see you, not necessarily so you can see anything else, though. We messed around with head lamps and will continue to do so, but I want a new light.

Am I correct in understanding that it is not DOT approved, and if you want to make it so, then you must buy a different bulb that has a high/low beam?

I'm suprised it doesn't come with a cage.

Yeah it's not a DOT light but I just run it aimed a ways down on the street and haven't had any issues with people flashing me etc. There is a guy on ADVrider that makes a DOT legal lens conversion kit for this light setup if someone wants it to be DOT legal. His kit will give you a high/low beam. So far I like mine with the single element just fine.

Hodakaguy

Thanks, good to know.

But no cage to cover the lens? My main riding partner is Captain Husaberg, aka Sir Roostsalot. I've been meaning to order a hockey neck guard.

(And please don't suggest riding in front of him, instead of behind him; that aint gonna happen. )

well then try riding beside him?

Chris6_85 wrote:

well then try riding beside him?