mc_racer
01-06-2011, 09:19 PM
Time for me to make an attempt at contributing something useful.
I've been trying to figure out a way to bypass the TORS switch at the throttle. I want it to be automatic, that way I can't forget to push the switch or whatever.
So I cut the wires off the switch and played around with how they work. What I found was they need to be open for the quad to start, but it won't rev past idle when they are open. They need to be closed for the quad to run properly once started. So I need them unconnected to start and connected to run. Easy enough. I just need a relay to operate this, but you need a normally closed relay, meaning it connects the wires when it does not have a signal and disconnects them when it does have a signal. Now you need something to signal the relay but only when you are pressing the starter button. I tested the clutch switch and found that it only gets power when the started button is pressed. Perfect, I've been wanting to eliminate that anyway. I found a relay at NAPA, part number AR143, for $7.50. It's actually a 5 pin relay, meaning you can wire it to be normal open or normal closed.
First thing to do is cut the wires at both the clutch switch and TORS switch. I cut them about 8 inches for the connector.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/ec5d0317.jpg
The yellow and brown wires go to the clutch switch, strip them, twist them together, and crimp a female spade terminal on them. By twisting them together, you have bypassed the clutch switch and we are going to use the spade terminal to activate the relay.
The two black wires go to the TORS switch. Strip them and put a female spade terminal on each one.
Grab your relay. Connect the clutch switch wires to the "85" terminal on the relay. Connect the one TORS wire to the "87a" terminal and the other to the "30" terminal. Now you will need a few inch of wire for a ground on terminal "86". Run that to a chassis ground. The last terminal won't be used.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/d660dc7d.jpg
Now bolt it down to the frame. Sorry for the blurry pic. It's bolted down next to the fuse panel under the hood. You can also see how I ran the ground to the other bolt.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/a3e952e8.jpg
I also smeared a layer of liquid electrical tape over the terminal for protection.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/a9310f9b.jpg
Now you are good to go. When you press the start button, it sends power to the clutch switch wires, which activated the relay, which disconnects the TORS wires. Quad starts, you let off the starter button, the relay losses power, and it goes back to closed mode, connecting the TORS wires and letting the quad run normal.
This still needs to be test riden, but the garage dyno (rev test) says everthing checks out fine. Hopefully I get it out next weekend and can do a followup.
ETA, this has been working great since installed, but I did upgrade to a weatherpak style relay.
I've been trying to figure out a way to bypass the TORS switch at the throttle. I want it to be automatic, that way I can't forget to push the switch or whatever.
So I cut the wires off the switch and played around with how they work. What I found was they need to be open for the quad to start, but it won't rev past idle when they are open. They need to be closed for the quad to run properly once started. So I need them unconnected to start and connected to run. Easy enough. I just need a relay to operate this, but you need a normally closed relay, meaning it connects the wires when it does not have a signal and disconnects them when it does have a signal. Now you need something to signal the relay but only when you are pressing the starter button. I tested the clutch switch and found that it only gets power when the started button is pressed. Perfect, I've been wanting to eliminate that anyway. I found a relay at NAPA, part number AR143, for $7.50. It's actually a 5 pin relay, meaning you can wire it to be normal open or normal closed.
First thing to do is cut the wires at both the clutch switch and TORS switch. I cut them about 8 inches for the connector.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/ec5d0317.jpg
The yellow and brown wires go to the clutch switch, strip them, twist them together, and crimp a female spade terminal on them. By twisting them together, you have bypassed the clutch switch and we are going to use the spade terminal to activate the relay.
The two black wires go to the TORS switch. Strip them and put a female spade terminal on each one.
Grab your relay. Connect the clutch switch wires to the "85" terminal on the relay. Connect the one TORS wire to the "87a" terminal and the other to the "30" terminal. Now you will need a few inch of wire for a ground on terminal "86". Run that to a chassis ground. The last terminal won't be used.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/d660dc7d.jpg
Now bolt it down to the frame. Sorry for the blurry pic. It's bolted down next to the fuse panel under the hood. You can also see how I ran the ground to the other bolt.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/a3e952e8.jpg
I also smeared a layer of liquid electrical tape over the terminal for protection.
http://i230.photobucket.com/albums/ee104/mc_racer/ATV/KTM/a9310f9b.jpg
Now you are good to go. When you press the start button, it sends power to the clutch switch wires, which activated the relay, which disconnects the TORS wires. Quad starts, you let off the starter button, the relay losses power, and it goes back to closed mode, connecting the TORS wires and letting the quad run normal.
This still needs to be test riden, but the garage dyno (rev test) says everthing checks out fine. Hopefully I get it out next weekend and can do a followup.
ETA, this has been working great since installed, but I did upgrade to a weatherpak style relay.