How many people would like an ignition key delete?
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  1. #1
    Senior Member KTMATVHQ Member
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    Lightbulb How many people would like an ignition key delete?

    I keep seeing people post things about wanting to remove the ignition key switch and just have the tether or the handle bar switch. The problem with that is the battery will go dead since the ignition is left on. I think I have a way around that and I was wondering if I built something to do this how many people would want it?? Basically it will connect where the factory ignition switch plugs in and then connect to the handlebar switches and the tether switch. All power will be off until the starter button is pushed which will turn the ignition on and the starter, the starter will turn off once you release the button but the ignition will stay on until either the tether is pulled out or the switch on the handle switch is flipped off. The starter wont run and the ignition will not turn on if the tether is out or the handle bar switch is flipped off. If I can find the connectors there wouldn't be any wire splicing either.

    I already designed a circuit which should work based on the wiring diagram so if enough people would like something like this I will start working on actually building it!
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro

  2. #2
    Administrator KTMATVHQ Guru
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    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  3. #3
    Administrator KTMATVHQ Guru
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    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

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  5. #4
    Senior Member KTMATVHQ Guru
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    id buy one as long as the price isnt way up there...



    -09 450sx- KTM slip-on, Bills a-arms, Rocket Ron WP's.

    -09 450sx- Bill's pipe, and a-arms, PEP Shocks, Baldwin head, Walt's dual squirt AP nozzle and 41.5mm bore.

    Both have Quadtech hoods, Ranchero carbs, Kiwi's spring mod, KTM Bill skidplates, High flow water pumps, KTM Bumpers, and Pro Armor Nerfs.

    2014 Sponsors- 38 Motorsports, Leatt Brace, Vertex Pistons, 100%, Lucas Oil, Jettrim, Streamline Brakes, Gaerne, KTMPartsHouse

  6. #5
    Senior Member KTMATVHQ Member
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    Thanks for the links kiwi!

    It shouldn't be super expensive, I'll see about getting some parts and start working on it then.

    Does anyone have the wiring diagram for the SX or is it the same? I only have the XC one.
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro

  7. #6
    Senior Member KTMATVHQ Addict

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    All you have to do is by the relay for the dirt bike with the wire harness it a done deal
    Chad Reed #90 Pro ATVA Nationals
    sponsor's 2013
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    Four Werx Carbon
    Web Racing Cams
    Dirt Tricks
    Skorbordz
    Volairathon Machining

  8. #7
    Senior Member KTMATVHQ Member
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    Doesn't the Dirt bike CDI run off a separate AC winding on the stator though meaning it only would get power when the engine was running?
    Last edited by tylerallout; 04-09-2013 at 10:33 PM.
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro

  9. #8
    Senior Member KTMATVHQ Addict

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    No same box runs off the battery you can run the quad with out the stator it's to run the light, fan and charge the battery voltage regulator can be removed to that is to keep it at 12 volts so you don't blow out the lights
    Chad Reed #90 Pro ATVA Nationals
    sponsor's 2013
    ALL 4 RACING L.L.C. Racing products Bills Headers

    a4rheaders.com

    Village Motorsports
    PEP Racing Shocks
    Four Werx Carbon
    Web Racing Cams
    Dirt Tricks
    Skorbordz
    Volairathon Machining

  10. #9
    Senior Member KTMATVHQ Member
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    What do you all do to the harness when you get rid of the key so that the battery wont go dead? Mine killed the battery when I left if on one time.
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro

  11. #10
    Senior Member KTMATVHQ Addict

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    Put a kill switch in line I use a tether switch then you pull the tether it is on put it in it disconnects the battery or if you like the handle bar switch you can wire that as the on off switch
    Chad Reed #90 Pro ATVA Nationals
    sponsor's 2013
    ALL 4 RACING L.L.C. Racing products Bills Headers

    a4rheaders.com

    Village Motorsports
    PEP Racing Shocks
    Four Werx Carbon
    Web Racing Cams
    Dirt Tricks
    Skorbordz
    Volairathon Machining

  12. #11
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    I thought about that but I didn't really like the idea of a tether switch that is closed when the tether was inserted. My idea was to make it so the ignition would remain off whether the tether is connected or disconnected and the handlebar switch is on or off. The ignition will come on automatically when the start button is pushed.
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro

  13. #12
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    Here's what I did, but like you mentioned it requires a normally-closed tether switch (circuit is closed when the tether is attached)

    -Unplug stock tether switch, leave it unplugged (It's a normally-open switch so the motor still runs with it just left unplugged, it can't tell any different)
    -Remove the handlebar 'switchblock', unplug the 4-wire plug off of it for the lights, then this leaves another 4-wires going to the switch:

    -2 of these wires are for the starter button, and 2 of the wires are for the on/off slide switch

    So I got a dirtbike style handlebar mounted single button killswitch, and wired that to the starter wires...this single handlebar switch is now my start button

    For the on/off switch wires, I wired in a normally-closed tether switch to these two wires and mounted the tether in the same place the stock tether was (the new tether looks the same as the stock one)...this acts as my master shut off switch, killing all power

    *I already have my ignition key switch already completely removed also by the way*

  14. #13
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    the way I got rid of the key switch and all the lights was to order a 2010 sx atv power harness and regulator and you will need a relay not list in parts ,I will look up the part numbers need ,I have them in the shop ,when I bought mine I bought 2 of each
    Thanks to my 2012 sponsers
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  15. #14
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    With the 2010 harness does the fan shut off when you kill the engine? What seems to be the difference between the two harnesses that you could see?
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro

  16. #15
    Senior Member KTMATVHQ Addict

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    Yes it will the relay that Andrew is talking about will cut the power
    It work just like a kill switch the easy way is to get a normally open switch then then you pull the cord it will disconnect the hot wire
    I think I got that right open switch would be open then the cord is pulled
    Chad Reed #90 Pro ATVA Nationals
    sponsor's 2013
    ALL 4 RACING L.L.C. Racing products Bills Headers

    a4rheaders.com

    Village Motorsports
    PEP Racing Shocks
    Four Werx Carbon
    Web Racing Cams
    Dirt Tricks
    Skorbordz
    Volairathon Machining

  17. #16
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    here is the 2010 sx atv parts number wireharness 83511275050 , voltage regulator 83011034100 , power relay 61111057000
    Thanks to my 2012 sponsers
    Powersportsplus
    www.powersportsplus.com
    Twinair
    www.twinairusa.com

  18. #17
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    There are a lot of links here, did we ever find a simple solution? I would like this for my 525xc. Also, what's the best start button assembly to buy to replace the stock/headlight switch?

  19. #18
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    Start button...Kill Switch KTM ATV Motorcycle Dual Sport Dirt Bike Start Horn EXC MXC Button MX | eBaysimple solution.... no not really, but you have a few options... wire a off on switch on the handlebars in place of key, wire in a normally closed tether in place of key, since you have an xc i dont think you can run the 2010 sx harness, but maybe you can.



    -09 450sx- KTM slip-on, Bills a-arms, Rocket Ron WP's.

    -09 450sx- Bill's pipe, and a-arms, PEP Shocks, Baldwin head, Walt's dual squirt AP nozzle and 41.5mm bore.

    Both have Quadtech hoods, Ranchero carbs, Kiwi's spring mod, KTM Bill skidplates, High flow water pumps, KTM Bumpers, and Pro Armor Nerfs.

    2014 Sponsors- 38 Motorsports, Leatt Brace, Vertex Pistons, 100%, Lucas Oil, Jettrim, Streamline Brakes, Gaerne, KTMPartsHouse

  20. #19
    Administrator KTMATVHQ Guru
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    KTM 505 SX: Web cams / 13.5:1 custom CP / balanced and modded crank / custom Vortex X10 ignition / Ported head / 43.5mm billet centre bored carb / KTM Akrapovic muffler / Mino hi vol water pump / 12 deg flexx's / houser stem / elka 5 / PEP PB1's and PEP LT rear / Walsh Flow A Arms / Quad tech seat & Foam / CF nose / FCI intake / relocated batt box / KTM Bill header / KTM factory SS Oil Pump setup / Manual cam chain tensioner Next round of mods: oil cooler........ the NEW TOP DOG 114 hrs…. best race engine I've owned

    KTM 554 XC
    : sx style crank, light weight SXF flywheel, TT sxf stator, steel linered cylinder, custom JE piston ceramic coating, plus 1 ported head / 807 cam, 43.5mm carb. Mino hi vol water pump. KTM Bill custom exhaust, FCI intake, JB A Arms, PEP PB1s front LT and rear , Lonestar axle, 12 deg Flexx's, CF nose, elka 3 steering damper, KTM factory nerfs, factory white plastic and graphics / gell cell battery Next round of mods: oil cooler........

    gotta stop spending $$$ on these KTM's...…..

    Polaris Outlaw 525 IRS - 2011
    , lonestar plus 2 A Arms, cut MXR front shocks (minus 1 ") with ZPS / ttripple rate, FUJ rear suspension rear shock mount units drops ride height 2", FUJ HD adj sway bar, 1.5” rear billet wheel spacers, Polaris nerfs, bumper and rear rack, Yoshi competition slip on, Pro Taper bars, acerbis hand guards, Trailtech GPS with billet protector. KTM throttle / Honda Front master cylinder and shorty lever / 41mm carb & hi flow intake runner / big filter / Billet FCR transition ring. Modified rear spring package / rear revalve.

    next round of mods: 8/33 cam, Hi Flow water pump and 540 cylinder / wossner piston waiting to go in, fastway 3 steering damper ala KTM setup, custom header using KTM XC header as a starting piece, light flywheel setup.
    gotta have something to modify this year !

    LTR 450
    , My Wife Nicola's ride & my back up mxer - 493 BB / JE piston / special order Yoshi motard cams / custom fueling map / tcs LT ZPS front end setup, TCS rear ZPS revalve / ims tank / TB exhaust / power commander / proflo - K&N / 14 deg flexx's / race nerfs / armadillo bumper/ Denton damper, next round of mods: ported head and carillo rod...... the clark kent of the ATV trio ! 210 hrs and still going strong ! the BB kit transformed this machine, it hauls the mail now !!!!

    A garage full of wheels and tires for them all........ speedway / sand / MX / cross country, over 30 at last count all on rims ready to rock

    NZ # 1 Vets champ 2013
    NZ Vets (40+) North Island MX champ 08, 09, 12 & 13
    NZ TT champ Vets (40+) 06, 08, 09,12 & 13
    Auckland ATV Club Sprint Series Champ 04, 05, 06, 07, 08, 09, 11, 12 & 13
    hope to get a good season in for the remainder of 2014.......finding time to ride being the biggest problem !

  21. #20
    Senior Member KTMATVHQ Member
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    Nov 2011
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    Finally got the prototype built although I can't test it on the quad since it's kind of in pieces but it works on the bench. Its way simpler and cheaper than running the sx harness and I designed it so that it will be plug and play once I get the connectors for it at least, been too lazy to order them.

    Here's a quick video of it working:
    2008 ktm 525xc: 95mm CP 13:1 piston, 41mm carb, 807 cam, +1 Kimblewhite valves, Racers Edge porting, FMF exhaust with powerbomb, SX intake, Crank Works Balanced Crank, DJH pressure feed for right main bearing and cup for left main bearing, mino hiflow water pump, All 4 Racing A-arms, LSR Axle, Rocket Ron Suspension

    My 2014 Sponsors:
    GPS Offroad Products, Elka Suspension, Risk Racing, Twin Air, Lonestar Racing, GoPro


 
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