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Old 04-12-2009, 02:49 PM   #61
azcagiva
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Joined: Apr 2007
Location: Camp Verde, AZ
Oddometer: 1,136
I did a little work on the bike today. I am still waiting on the gasket for the stator so I decided to do what I could.

I installed a small relay for the lights. I made a small wiring harness and ran it to the front of the bike. The relay is set up so it will trigger when I ground the wire I ran to the front of the bike. I also installed the small regulator/rectifier that I had.

Here is a pic of the under seat area


Anyone have any recommendations for a small handlebar switch?

-John
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Old 04-12-2009, 05:41 PM   #62
winterhk
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Joined: Dec 2004
Location: Cape Coral, FL
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Johnm, check out these guys: Highway Dirtbikes
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Old 04-12-2009, 07:32 PM   #63
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Location: Groves,TX
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I have a switch from Paul at Highwaydirtbikes.com I really like it.
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Old 04-12-2009, 10:43 PM   #64
winterhk
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Location: Cape Coral, FL
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Quote:
Originally Posted by Behindbars
I have a switch from Paul at Highwaydirtbikes.com I really like it.
How do you like that hydraulic clutch? Got any more pics of it? Any issues?
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Old 04-13-2009, 06:23 PM   #65
Behindbars
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Location: Groves,TX
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Quote:
Originally Posted by winterhk
How do you like that hydraulic clutch? Got any more pics of it? Any issues?
Actually that is a LH rear brake. No clutch lever. I run the Rekluse.
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Old 04-14-2009, 05:54 PM   #66
azcagiva
new orange flavor
 
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Joined: Apr 2007
Location: Camp Verde, AZ
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I was able to get the stator back on the bike today. I finished the wiring and fired it up. The battery at rest is around 12.5 . With the bike idling and the light on its 12.39, a little throttle and the voltage is 13+.

I think it is gonna work. Now I just have to get the switch and mount the ballast. Hopefully everything stays together.

I am happy with the light and it is stupid bright, hurts to look at the reflection on the wall.

-John
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Old 04-14-2009, 11:59 PM   #67
Road Hog
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Joined: Mar 2009
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putting a big light on is the best thing you'll do. the day will never end
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Old 04-15-2009, 06:18 PM   #68
haggeo
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Joined: Aug 2005
Location: oakland, ca
Oddometer: 870
Quote:
Originally Posted by azcagiva
I am in the process of setting up the xr for a large HID. I talked to ricky stator and he informed me that for the size of HID I am planning on using I would need a decent battery to help it start. So I purchased his 200w stator and rectifier/regulator.

Today I looked all over the bike and could not find any place to mount the crf 450 battery that I had just bought. It was the smallest that I could find here in the small town of Camp Verde. I finally decided on putting at the back of the bike behind the airbox. I fabbed up a battery box and mounted it. I wish the battery was a little slimmer but I think it will work ok. Anyone else try this?

Here are some pics of the box I made.




I now need to make a small plastic cover to put over the terminals. I tried the battery the other way but the positive terminal was too close to the mounting bolts, didn't want to short out the battery.

I will install the stator and regulator later this week. I am still waiting on some parts so I can fab the front light. I think I will use a trailtech cage to mount my reflector and ballast.

What do you guys think? Does it look ok or should I start over?

-John
i have a similar battery mounted on my bike using a tray sold by Baja Designs. the tray goes mounted above the engine behind the stator. the way yours is set up looks good but it will take a pounding, i wonder if it will hold in the long run. this is the best picture i have right now of my set up, the battery is right behind the e-start (previous owner install) i'd like to get rid of but love when i'm too hot and tired to kick it's a great location for the battery, well protected and solidly mounted to the engine.
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Old 04-16-2009, 08:08 AM   #69
azcagiva
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Location: Camp Verde, AZ
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I thought about mounting the battery under the tank like yours, but the battery that I have was a little too big. What battery are you using? I was thinking that mine may not hold up so I need to keep my options open.

-John
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Old 04-16-2009, 10:41 PM   #70
haggeo
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Location: oakland, ca
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Quote:
Originally Posted by azcagiva
I thought about mounting the battery under the tank like yours, but the battery that I have was a little too big. What battery are you using? I was thinking that mine may not hold up so I need to keep my options open.

-John
i have the yuasa YTZ 7S.
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Old 04-17-2009, 08:01 PM   #71
azcagiva
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Joined: Apr 2007
Location: Camp Verde, AZ
Oddometer: 1,136
Finished the bike today. I really like the highway dirtbikes switches that I got. I tied one into the kill switch to slow the dirtbags down if they try to steal it. That and the padlock through the rear rotor should work.





-John
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Old 05-09-2009, 07:44 AM   #72
4play
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Joined: Feb 2008
Location: Avondale, AZ
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I have a BD 125w x 2 stator. I was running half AC, half DC. I have decided to convert to an all DC system & a HID headlight setup. I talked to BD, they said I could combine the AC leads into one input to the rectifier. On John's advice I have a 250w RS rectifier coming and I'm looking at a smaller battery option to help light a 40w HID
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Old 05-26-2009, 01:58 PM   #73
4play
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Location: Avondale, AZ
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My buddy John with me as his helper built a light cage for my XRR.
I'll be using the same KC reflector as he's using on his with a 55w HID. For now I have it mocked up with his spare BD halogen.









Thanks John!
I need a bit more battery to run it & possibly a wiring upgrade. It only needs 55w's to run, but it seems to need way more than that to warm up.
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Old 05-26-2009, 11:56 PM   #74
DRBImagery
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Joined: Mar 2009
Location: Alberta Canada
Oddometer: 65
Vancouver Super Moto Harness

Im running a different harness system that the BD, I didnt like the quality of the BD stuff and I found a very cool, well designed harness built by Vancouver Super Moto in Canada, its pricey but worth it, good peeps to deal with over the phone and excellent service. Im running a split ac/dc system with dual 5 3/4" 55 watt lamps up front in a Simpson offroad fairing. will post pics in a while,,,,,great thread going here! Gotta love the XR crowd

DRBImagery screwed with this post 05-28-2009 at 12:37 AM
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Old 05-27-2009, 09:10 PM   #75
*Ck*
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Joined: Aug 2008
Location: Calgary, AB
Oddometer: 58
hey drb, where about in alberta are you?
I just picked up the same kit, vancouver Supermoto right?

Anyways, i'm having an issue with my headlight ( not working) let me explain:

HAve 200w stator spit into 2x100, 1 ac system for headlight, 1 dc system for everything else, dc system is workin perfect.
The ac system gets power through a single wire that goes from one of the stator coil wires to the stock ac regulator that was replaced with a dc one that came with the kit.
So...power from stator plugs into the positive (white/yellow) on the regulator and then from the positive dual female end a wire goes to power on headlight.
theres a wire from the negative on the headlight that goes to a negative on the ac regulator and a wire that grounds to the frame from the negative dual femal end.

Now, from what i've been reading i need to "float the ground" (ie. take it off), will this solve my problem?

cheers

Ck
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