I'm looking to dual sport my KTM450 EXC. It already has a regulator and rectifier if I understand correctly. And I picked up a used XT 350 light/horn/turn signal switch. Now I'm ready to wire up the turn signals ect...

My questions are:
Can the handle bar switch handle enough current to wire it in-line between the power and lights (head light, turn signals), or do I need relays.

And will I need an additional rectifier, or can I just splice into the stock head light feed, or even straight off the battery terminals?

I'm not familiar with factory bike wiring and if they use relays, etc...

Thanks for your help!!!

No relays necessary. The stock headlight feed should also work fine. That's what I did on both my and my son's WR's.

Not sure about the KTM's but the later WR's ('03 - Present and I believe the CRFX's) use two magneto's. One is rectified and supplies DC (~25 watts) to charge the battery. The other is AC and supplies the headlight/taillight. If KTM's are similar you have a couple of choices. One way is to rewire the stator to convert the whole bike to DC. Here's a link on how to do the conversion ->

http://www.trailtech...version_ktm.pdf

The other method is to run the taillight, turn signals & horn off the battery and leave the headlight on the AC magneto. To do this you will need a relay to switch the headlight (hi/lo) since you cannot combine AC and DC in the same handlebar switch.

The KTM is factory wired for a head light and a tail light. I assume both are AC? If so is it fine to run the UFO headlight and tail light off AC and just use DC for the turn signals and the brake light?

Any reason not to just use the KTM pull switch for head light hi/lo other than it's bad location?

Is there a best way to mount the UFO tail light/turn signal assembly?

BTW Thanks!!

In CA the taillight (and only the tailight for some reason) has to be able to operate for 15 minutes with the engine off so to be legal you need to rewire it to the battery. Don't know about Alabama? When I did my WR450 I put the taillight, brakelight, turn signals & horn on the battery circuit. I left the headlight on the AC magneto and used a relay in place of the factory switch so everything operates off the handlebar switch but there's really no reason you couldn't just use the factory switch for the headlight.

Read this and most of your questions will be answered, I think.

RFS Stator Rewind

No, you do not need relays - only high amp devices like the starter motor need a relay. The lights sure don't, and even the radiator fan doesn't need one.

You can just hook up the new light to your ac lighting circuit, but it will work much better if you convert to a full dc system. Do NOT hook the light power input right to the battery positive post - the stock dc charging system only puts out a couple of amps and your battery will go flat in a "minute less than no time", as they used to say on Mr Roger's Neighborhood.

John Davies
Spokane WA

In Alabama technically you only need a brake light and a horn to be daytime street legal... But to be safe I want blinkers and a head light in case I do get caught out in the dark. I rather not ride at night though, especially on the road. My goal is just to be able to put around locally and maybe ride to class (3 miles away) when I get the need to ride, but can't make it to a trail.

From the info I've gathered over the last two days, I think I'll run the head light and tail light off AC just like the factory does and come off the battery just to run the blinkers, horn and maybe break light. Similar to PBDBLUE. I also plan to make it easily detachable for pure off road use. That will also be minimally invasive to the factory wiring which I think is a plus come resale time. I think rewinding the stator and going full DC is overkill for my goals. The only thing extra I'll be adding to the factory setup is blinkers, horn and brake light, all of which use little power and are only on for short burst.

Just need to find a good way to mount the UFO tail light now. The plastic on it is to short to reach the sub frame and I don't what to rivet it to the tail fender...

Thanks for all your help.