[tylerallout]

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!

 

[kiwi-craig]

try these guys

Corsa Technic Motorsport, Motorcycle Connectors

 

[kiwi-craig]

try these guys


http://www.cycleterminal.com/


http://www.qualitycycleparts.com/motorcycle_connectors_s/7587.htm


http://www.kojaycat.com/Motorcycle connector.htm

 

[5lblmbn2009]

id buy one as long as the price isnt way up there...

 

[tylerallout]

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.

 

[ktmbill]

All you have to do is by the relay for the dirt bike with the wire harness it a done deal

 

[tylerallout]

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?

 

[ktmbill]

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

 

[tylerallout]

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.

 

[ktmbill]

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

 

[tylerallout]

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.

 

[colt53]

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*

 

[andrew75]

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

 

[tylerallout]

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?

 

[ktmbill]

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

 

[andrew75]

here is the 2010 sx atv parts number wireharness 83511275050 , voltage regulator 83011034100 , power relay 61111057000

 

[KTMNewB]

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?

 

[5lblmbn2009]

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.

 

[kiwi-craig]

http://sicassracing.com/store/products/switches/sicass_switches/ktm_start_kill_switch_2004-12_various_ktm

reduces the clutter with the stock switch gear…….

 

[tylerallout]

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:
[video=youtube;hs0Hs2F8OWA]http://www.youtube.com/watch?v=hs0Hs2F8OWA[/video]