How to Turn a YZ400F into a Dual Sport

Discussion in 'Some Assembly Required' started by Clew540, Mar 19, 2011.

  1. Clew540

    Clew540 Ready to Ride

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    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.
    #1
  2. Clew540

    Clew540 Ready to Ride

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    <a href="https://picasaweb.google.com/lh/photo/tO5WJqIAyx98oeY3QYsl_w?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_6VshZ0cidpE/TYVQ94GozBI/AAAAAAAAASw/buiD66rsBR4/s640/SANY0030.JPG" height="479" width="640" /></a>

    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 :evil
    #2
  3. Clew540

    Clew540 Ready to Ride

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  4. Clew540

    Clew540 Ready to Ride

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    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.
    #4
  5. Clew540

    Clew540 Ready to Ride

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    Now since i got the dual sport kit i had to strip the bike down to wire it up.
    #5
  6. Clew540

    Clew540 Ready to Ride

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  7. Clew540

    Clew540 Ready to Ride

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    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.
    <a href="https://picasaweb.google.com/lh/photo/oGg1jc8EKGHt9s5UBiFR_dIO6KEqPe5imtbj4NBmFEs?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/_6VshZ0cidpE/TYVMQdebH0I/AAAAAAAAARg/eB4v5V7xp88/s640/SANY0078.JPG" height="479" width="640" /></a>
    #7
  8. Clew540

    Clew540 Ready to Ride

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    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.
    #8
  9. Clew540

    Clew540 Ready to Ride

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    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.
    #9
  10. Clew540

    Clew540 Ready to Ride

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    Headlight mounted.
    #10
  11. Clew540

    Clew540 Ready to Ride

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    Of course the kit doesn't come with holes for the rear turn signals so i had to mark and drill holes.
    #11
  12. Clew540

    Clew540 Ready to Ride

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    Look at all this extra wiring!

    <a href="https://picasaweb.google.com/lh/photo/NZ0DwwajjU7qohSEISjHX9IO6KEqPe5imtbj4NBmFEs?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_6VshZ0cidpE/TYVMWXTqYgI/AAAAAAAAASE/NsfhHxtwRYM/s640/SANY0083.JPG" height="479" width="640" /></a>
    #12
  13. Clew540

    Clew540 Ready to Ride

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    SO i got out the zip ties and made wiring dissappear.
    #13
  14. Clew540

    Clew540 Ready to Ride

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    Now i have this mess to deal with but i got it hidden as well i love open air boxes.:1drink

    <a href="https://picasaweb.google.com/lh/photo/J_FqxyOmAPhLqH5xbqq9ztIO6KEqPe5imtbj4NBmFEs?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_6VshZ0cidpE/TYVMZV_SCgI/AAAAAAAAASU/ewzN7Qt7PAA/s640/SANY0086.JPG" height="479" width="640" /></a>

    <a href="https://picasaweb.google.com/lh/photo/dklpEqZH2w0gSojMa9vATdIO6KEqPe5imtbj4NBmFEs?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/_6VshZ0cidpE/TYVMZenAskI/AAAAAAAAASQ/s9z0NZmuF_E/s640/SANY0087.JPG" height="479" width="640" /></a>
    #14
  15. Clew540

    Clew540 Ready to Ride

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    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.

    <a href="https://picasaweb.google.com/lh/photo/SlhEd9EMiX_3NYFSrYF_HtIO6KEqPe5imtbj4NBmFEs?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/_6VshZ0cidpE/TYVMa4cEfII/AAAAAAAAASY/8hUcfjxM3YI/s640/SANY0088.JPG" height="479" width="640" /></a>
    #15
  16. Clew540

    Clew540 Ready to Ride

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    <a href="https://picasaweb.google.com/lh/photo/XArMoqWugZoMPFd8iS5yR9IO6KEqPe5imtbj4NBmFEs?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/_6VshZ0cidpE/TYVMbzMnwQI/AAAAAAAAASk/NAkG90NxVNo/s640/SANY0090.JPG" height="479" width="640" /></a>

    Almost looks like a WR.
    #16
  17. whisperquiet

    whisperquiet Long timer

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    Looks great..........clean, tidy, and ready to explore.
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  18. D.T.

    D.T. Difficult but useful

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    How did you get a licence plate for it? I hear AZ is fairly easy. Just walk in and say "I give you money, you give me plate!" (Even though it's for a riding lawn mower with a beer keg and tap)
    #18
  19. Clew540

    Clew540 Ready to Ride

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    Well that is how i turned my YZ motocross bike into a dual sport and give a special thanks to Doc and Mossycreek with out them i would still be riding a motorcross bike instead of a now dual sport.
    #19
  20. Clew540

    Clew540 Ready to Ride

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    Well here all you do is pass emissions and go to the dmv and they give you a plate.
    #20