How to Turn a YZ400F into a Dual Sport

Clew540 · 03-19-2011, 06:29 PM

I am currently in Phoenix AZ. I am a student at MMI which i will be graduating soon and cant wait. I have a 1998 YZ400F and thought about making it dual sport. So i looked into what it would take. Looked two different ways of doing one was converting the whole electrical system over to a WR. Then found that baja designs once made a external stator for the bike. This stator is a output of 180 watts. So i figured that would be my best bet its a direct bolt on and there is no "i hope this fits" thoughts going on when u buy something. So i searched around and found one. And I bought it being it was used i was kinda questioning whether it works or not. I got it and put it on the bike and tested it and it is producing AC Voltage. So then i shopped around for a dual sport kit and got a baja designs. Had to go to ricky stator and get a higher reg/rec being that the stator is suppose to produce up to 180-200 watts and the baja designs only handles 100watts. I wanted a full DC system.

Clew540 · 03-19-2011, 06:32 PM

As you can the stator justs bolts to the outside of the existing stator and flywheel. It replaces the stator cover and adds about 12 ozs of weight to the flywheel which made the bike more torguey

Clew540 · 03-19-2011, 06:33 PM

Clew540 · 03-19-2011, 06:35 PM

Got the new stator on as u can see it sticks out a little further than the stock cover so mods to the shifter had to be done which ment geting a steal shifter so it can be bent and it works for now.

Clew540 · 03-19-2011, 06:37 PM

Now since i got the dual sport kit i had to strip the bike down to wire it up.

Clew540 · 03-19-2011, 06:37 PM

Clew540 · 03-19-2011, 06:39 PM

I had to drill hole in the rear fender to mount the new tail light and brake light assembly and it turned out great i think.

Clew540 · 03-19-2011, 06:42 PM

As some of you know the older four strokes had a manuel decomp. I notice that the new switch houseing was giving me an issue being i have to have the decomp the start the bike but i got it to work and it seems to be in a better spot than before cause now i can pull the lever with just my index finger. Wish i had it there the whole time.

Clew540 · 03-19-2011, 06:45 PM

As mentioned earlier i had to buy a reg/rec to handle the larger output so i had to study how the baja designs was wired and make the new one the same.
old on left new on right. To look at the back of the headlight u would never know i switched it.

Clew540 · 03-19-2011, 06:46 PM

Headlight mounted.

Clew540 · 03-19-2011, 06:47 PM

Of course the kit doesn't come with holes for the rear turn signals so i had to mark and drill holes.

Clew540 · 03-19-2011, 06:48 PM

Look at all this extra wiring!

Clew540 · 03-19-2011, 06:49 PM

SO i got out the zip ties and made wiring dissappear.

Clew540 · 03-19-2011, 06:51 PM

Now i have this mess to deal with but i got it hidden as well i love open air boxes.

Clew540 · 03-19-2011, 06:54 PM

I didnt get pics of puting in the brake switch but hey it just replaces the banjo bolt and you got to bleed the brakes. I got that done all the wiring put away so time to put the bike back together and start it up.

03-19-2011, 06:29 PM	#1
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	How to Turn a YZ400F into a Dual Sport I am currently in Phoenix AZ. I am a student at MMI which i will be graduating soon and cant wait. I have a 1998 YZ400F and thought about making it dual sport. So i looked into what it would take. Looked two different ways of doing one was converting the whole electrical system over to a WR. Then found that baja designs once made a external stator for the bike. This stator is a output of 180 watts. So i figured that would be my best bet its a direct bolt on and there is no "i hope this fits" thoughts going on when u buy something. So i searched around and found one. And I bought it being it was used i was kinda questioning whether it works or not. I got it and put it on the bike and tested it and it is producing AC Voltage. So then i shopped around for a dual sport kit and got a baja designs. Had to go to ricky stator and get a higher reg/rec being that the stator is suppose to produce up to 180-200 watts and the baja designs only handles 100watts. I wanted a full DC system. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:32 PM	#2
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	As you can the stator justs bolts to the outside of the existing stator and flywheel. It replaces the stator cover and adds about 12 ozs of weight to the flywheel which made the bike more torguey __________________ Love the power of big bore two strokes!!

03-19-2011, 06:33 PM	#3
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	__________________ Love the power of big bore two strokes!!

03-19-2011, 06:35 PM	#4
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	Got the new stator on as u can see it sticks out a little further than the stock cover so mods to the shifter had to be done which ment geting a steal shifter so it can be bent and it works for now. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:37 PM	#5
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	Now since i got the dual sport kit i had to strip the bike down to wire it up. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:39 PM	#7
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	I had to drill hole in the rear fender to mount the new tail light and brake light assembly and it turned out great i think. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:42 PM	#8
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	As some of you know the older four strokes had a manuel decomp. I notice that the new switch houseing was giving me an issue being i have to have the decomp the start the bike but i got it to work and it seems to be in a better spot than before cause now i can pull the lever with just my index finger. Wish i had it there the whole time. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:45 PM	#9
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	As mentioned earlier i had to buy a reg/rec to handle the larger output so i had to study how the baja designs was wired and make the new one the same. old on left new on right. To look at the back of the headlight u would never know i switched it. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:46 PM	#10
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	Headlight mounted. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:47 PM	#11
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	Of course the kit doesn't come with holes for the rear turn signals so i had to mark and drill holes. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:48 PM	#12
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	Look at all this extra wiring! __________________ Love the power of big bore two strokes!!

03-19-2011, 06:49 PM	#13
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	SO i got out the zip ties and made wiring dissappear. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:51 PM	#14
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	Now i have this mess to deal with but i got it hidden as well i love open air boxes. __________________ Love the power of big bore two strokes!!

03-19-2011, 06:54 PM	#15
Clew540 ^OP Ready to Ride Joined: Feb 2009 Oddometer: 86	I didnt get pics of puting in the brake switch but hey it just replaces the banjo bolt and you got to bleed the brakes. I got that done all the wiring put away so time to put the bike back together and start it up. __________________ Love the power of big bore two strokes!!

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