Fitting current model KTM headlight & LED taillight to FS650

G'day,

I picked up a 04 FS650e a few days ago and I immediately stripped it down to give it a once over and also fit a few parts. One of the things I am doing is fitting a 08-12 KTM headlight and a generic LED tailight and I have a couple of wiring questions. I know I am not the first to do these mods so I am hoping someone can help me.

1. The original headlight has 5 wires while the new one has a pre-fitted plug with only 4 wires. Any tips on which colour wires go where and what I do with the one left over? My current plan is trial and error but with that number of wires it could take some time to get he combination right.

2. The bike is stripped to the point of not being able to run so can someone please confirm that the tail light and headlight won't work unless the engine is running? I tested all the electrics prior to stripping but the bike was running when I did it. How about the brake light does it need the engine on? The reason i ask it that I fitted the new tail light and neither the brake or tail light will function. Indicators work OK though.

Thanks for your time.

Re: Fitting current model KTM headlight & LED taillight to F

The fifth wire is probably for the parking bulb in the old headlight. New bikes are DC so The lights are on with the key. I'd use a test light to Figure it out. You can hit the starter while holding the kill button and it won't start. Pull the decompression lever too. It will make just enough power to dimly light the head and tail light.

I'm guessing it's not the same color wires.. Good luck and take a pic or two for me please?

Re: Fitting current model KTM headlight & LED taillight to F

Needs to be running to work. Post some picks was looking at puting a new ktm light on my F650 2004 too.

Re: Fitting current model KTM headlight & LED taillight to F

Thanks for the input guys. Messed around with it today with partial success using the starter motor method. I am waiting on some engine parts so I will re-attack the lights once the motor is up and running. Took a few photos and I will provide a full report when I am done.

Re: Fitting current model KTM headlight & LED taillight to F

OK bike is running so I played around with the head light and tail light today.

Few initial issues.

1. Head light worked but was very dim on both high and low beam with the bike running.

2. Tail light did not work when the headlight was on but worked fine when the front or rear brake was applied. There are 3 wires on both the old and the new tail light set up so it was just a matter of trail and error to match the wires.

Progress?

I disconnected the tail light wire that I am pretty sure is for illumination when the headlight is on (not brakes) and immediately the head light went bright.

Not sure what the link is between head light and tail light here? The led tail light should be using less power than the old tail light and should not effect the headlights power?

Any thoughts? Cheers.

Re: Fitting current model KTM headlight & LED taillight to F

One more thing, my battery is toast so I jump started the bike to get it to run. Could the dead battery be causing the problem? My simple (and could well be wrong) logic is that the stator takes care of all power required when the bike is running and the battery's output is irrevalent?

Re: Fitting current model KTM headlight & LED taillight to F

Sorted. In the end the problem was a faulty 'new' led tail light. I switched it out with one from another project and everthing worked straight away. With that problem eliminated it is a very easy conversion.

Fitting 08 - 12 KTM EXC Head Light

I cut the wires from the old headlight and cut off the pre fitted plug from the new headlight. It was then simply a mater of connecting the 3 same colour wires with bullet connectors. Brown to Brown, Green to Green and Blue to Blue - this gives high and low beam.

Additionally the small stand alone light bulb from the old light (hanging down in pic with the white & brown wires) plugs straight in where there is a similar bulb on the new head light. I just removed and hid away the one in the new light (+ it's wiring, not needed) and pushed the one from the old light straight into position - no need for cutting or new wiring with that bulb.

There is one white wire from the new headlight that is not needed, you probably could leave it hanging but I connected it into new head lights brown wire (earth) on the new headlight side of the bullet connectors using a t-piece style of connector.

LED Tail Light

3 wires on the old light, 3 wires on the new light. They were different colours so it took some experimenting to get the right combination to provide front brake, rear brake and tail light/number plate illumination. The trickiest part was mounting the LED light to the stock number plate holder, outcome was OK but I could do a neater job a second time.

Pics below and the lights were one of the last steps in my mostly cosmetic rebuild of the bike since buying it a couple of weeks ago. Few mechanical things I need to do still with most of the parts on their way to Australia
from Taffy - new battery, starter motor, starters gears, slipper clutch. That being said it starts easy now the valves are in spec.

Re: Fitting current model KTM headlight & LED taillight to F

Re: Fitting current model KTM headlight & LED taillight to F

Will it fit on the 2007 model? Mine doesn't even have an ignition & key. Also is it taken from a 530 KTM or a 690?