'17-'23 KTM Headlight Frame for Diode Dynamics LED SSC2

Change Log

V3

• Lower light bolt hole moved forward to allow for greater range of motion for lower light
• Reinforced the slot in the frame that interfaces with the lower headlight mount of the headlight mask.  

V2

• Overhangs improved for more reliable printing
• Modeled-in brim to reduce warping when printing in ABS 
• Added relief in frame to allow for 8mm socket to counter-hold nylock nut for light mount 

Required Hardware: 

• 4x M3x~5mm heatserts 
• 4x M3x8mm stainless steel countersunk bolts 
• 2x M5x5 to 8mm heatserts
• 2x M5x10mm stainless steel bolts 
• 1x M5x25mm stainless steel bolt
• 1x M5 standard nut 
• 2x M5x60mm stainless steel bolts
• 2x M5 nylock nuts
• 4x M5 nylon washers

Wiring:

KTM Wiring:

• Brown - 12v Negative/Earth
• White - Low Beam
• Blue - High Beam
• Green - Parking Light

KTM connector to mate to factory wiring: 
4 position MTW - Hitachi Type Connector for .110 - 2.8mm Terminal

Recommended upgraded connector: (requires specialized crimping tools)
Sumitomo 4  pin MT .090 - 2.3mm sealed connector  

Lights:

This LED headlight frame uses 2x Diode Dynamics SSC2 LED light pods. I chose the SSC2 Pro lights—one with a SAE driving optic and one with a “combo” optic.

• “Pro” power consumption (per light): Main Beam: 25.6w, Backlight: 0.7w
  • Diode Dynamics - SSC2 Pro Pod (No affiliation or monetary gain)
• “Sport” power consumption (per light): Main Beam: 7.7w, Backlight: 0.7w 
  • Diode Dynamics - SSC2 Sport Pod (No affiliation or monetary gain)

Note: If you have a carbureted bike, consider if the stator output is enough to handle the output of the lights. Baja Designs published an excellent chart that lists the outputs of each model & year. 

Fitment: 

This works with 2017 through 2022 (competition)/2023 (enduro) KTM dirt bike headlight masks. 

It is possible to upgrade a ‘12-’16 KTM with the ‘17-’23 headlight mask and fender, but be sure to do your own research to confirm fitment before attempting.

Printing tips:

• ABS, PA, PA-CF/GF recommended. Scaling the model as needed on the X, Y, and Z axis may be necessary, depending on your printer and filament. I recommend dimensional calibration on smaller objects to dial in the scale percentage for your filament. 
• For strength, ≥4 perimeters and ≥30% infill is recommended
• Orient the headlight frame face-down on the build plate. Some supports required.
• Add a brim to minimize warping to both the faceplate and the frame.