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Wiring issues Fan and Headlight 570

Joined May 2012
3 Posts | 0+
I just picked up a low mileage 2011 570 fe. The bike had never had the factory headlight installed, just the number plate. I fitted and plugged everything in but no light. No high beam, no low beam, nothing. There is no power at the connector but the fuses under the seat are all good. Thoughts?

I bought the KTM fan kit and installed it. The fan doesn't work. The inline fuse is good, I jumped the temp switch terminals and still nothing. I checked the factory power lead under the fuel tank and there's no power there. Again, the fuses under the seat are OK.

Any chance these two issues are related? What should I be looking now?

Thanks in advance.
 
Did you every resolve this issue? - There are two wiring harnessess; from the sound of it (jumping temp terminals, still no power) maybe connection feeding power to second (accessory) harness no good. (???)

And just curious, why no headlight install on factory FE 570? :?
 
The fan now works but it was a battle. I had power at the fuse block but now at the fan connector, then there was power then there wasn't etc. I clean up all the terminals (mud, debris etc) and it seems to be OK now.

The head light is another story. This bike was a factory street legal version that was converter to full dirt bike (de-smogged, comp fuel map, street legal bits pulled off etc). The head light and wiring were in a box with everything else when I got the bike. I mounted the light switch on the bars, ran the wiring harness and strapped the light on. Fired up the bike but no light. Checked fuse, it was good. Pulled out the test light and was getting weird intermediate results (sometimes power at the switch, sometimes not). I've had power at the fuse the whole time until tonight. Now there is no power on either side of the fuse.

I assumed there must be a short somewhere in the harness so I started poking around. In a couple spots (near the rear shock) it looked like someone had cranked the zip ties on really tight to the point that the insulation on the wires couple had been damaged causing a short. The wires are taped and in a loom so I had to pull all of it out.

The entire harness is out, cleaned, stripped and I didn't find a thing wrong with it. Now I'm annoyed because I had to cut all the rubber covering off the harness to inspect it. I can tape it but in several spots it needs to be flexible so the rubber covering would be best but I can't get new stuff on with all the connectors attached. Argh! I really don't want to be taking pins out of connectors to slide new covering on.

I'm going clean up all the terminals, re-wrap it and re-install it tomorrow. If the lights still don't work then they'll just get hard wired with a switch.
 
IMG2325-M.jpg
 
Man that sucks! :( I'm sorry to hear that you're going through that. That's a lot of work. I do wish the best of luck to you. Hang in there, maybe get a friend to help (he can hold your beers) and gett'er done. I'm sure you'll be very happy with the Berg once your done and you'll have one hell of a story. :) - Good Luck!
 
After pulling all that out and finding nothing I started tracing wires. The yellow and red feeds power to the lights and the black and green wire comes from the #3 fuse but I couldn't find any place they connected. They both run into a 6 pin connector behind the headlight though. On my bike this plug was taped up and unused. The connector is the same as the one that comes from the headlight switch. I thought that maybe when running as a straight dirt bike you are supposed to plug mystery plug into the male plug that the headlight switch goes in to. I gave it a try and they bike died. Popped a couple fuses.

Not sure what is supposed to be on the end of that mystery plug but clearly the previous owner took it off. The black/green power wire is in it and the yellow/red lead that runs to the lights is in it. Clearly it plugged into a relay or switch of some kind. I simply jumped the 2 wires and now all my lights work as they should and the power runs through the factory path including the stock fuse panel.

In the pic below the wire is orange instead of yellow/red because I broke the pin off while doing battle with this problem.

I never did figure out why the fan was sketchy. I ended up bypassing the original wiring and doing my own, now it works fine.

Hopefully someone else with a 570 can have a look to see what their mystery plug attaches to.

IMG0324-L.jpg

IMG0326-L.jpg
 
i know this is a very old thread but didn't want anyone else having problems in the above reply...

the 6 pin plug behind the front mask/headlight, IS the headlight harness. your headlight switch plugs into this, and a single pin plugs into the yellow/black kill switch wire.

if it's shorting when they're plugged together, find the short. most likely it's the small wires behind the speedo bracket, very easy to pinch a wire there between the metal connector bracket and top clamp....dont ask me how i know this.. :mrgreen:
 

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