KTM EXC Stator Information (530/450)

Discussion in 'Thumpers' started by Subaru297, Apr 4, 2012.

  1. James Adams

    James Adams non impediti ratione cogitationis

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    I've no idea how many miles I have on mine Electrosport stator now, but I ride it frequently and it hasn't given me any trouble.

    [​IMG]
    #61
  2. D K

    D K Been here awhile

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    Cool hand Luke.


    Nice to hear from you.

    I bought a 05 525 EXC for use here in Baja. Im stuck in Mexico for a year or so - needed to get a proper bike :D


    Would love to talk more bit im on the owners V Sat ......




    #62
  3. Subaru297

    Subaru297 Been here awhile

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    Knowing what I know now I am sure the 100W the Trailtech supplies will be sufficient for my needs. I didn't really understand before that the ignition is not using any of the 100W available so I thought I would have less than 100W to run accessories and charge the battery so I wanted the most watts I could get.
    As my bike sits right now it has a 10w led lowbeam, 35W heated grips, and 65W highbeam. If I change out the highbeam to a 40W led or 35W HID I would have more than enough watts to run full lights and grips indefinitely. Even as is I would be fine as I don't do any cold weather night riding where I would need everything turned on all the time.

    I am looking forward to getting the Trailtech unit installed and getting my bike running again!

    Cheers
    #63
  4. Subaru297

    Subaru297 Been here awhile

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    I got the Trailtech stator a couple weeks ago and installed it. The install was way easier than the electrosport. Truly plug and play. The only thing that took me a while was reversing all the crap I had to do to get the electrosport stator to work.

    I have only managed one commute into work on the bike (30 mins each way) and the stator seemed to work just fine. It also seems to start a little easier than before. I guess time will tell but I will probably feel better with the Trailtech in the bike. Hopefully it proves to be reliable. Winter has set in here so torture testing will have to wait until next year.

    I wish I went this route to begin with.

    Cheers
    #64
  5. K_N_Fodder

    K_N_Fodder Long timer

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    Subaru -

    Quick one for you from a mechanical engineer. What this means is that when people start talking about sparky stuff, I generally glaze over and pass out. But I can follow directions.

    With that said, I just installed a TT stator in my 2008 450 EXC. Easy peasy. What I don't understand is if I need to install their regulator/rectifier they supply - I guess I wasn't clear if I could just leave it alone with an AC system or if I'm forced to go DC.

    Thanks!
    Justin
    #65
  6. Subaru297

    Subaru297 Been here awhile

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    Hi Justin,

    Sorry I didn't respond earlier. I haven't looked at this thread in a long time.

    Hopefully you got this figured out already but yes I think you do need to install a DC reg as well if you installed the stator.

    Cheers
    #66
  7. Foot dragger

    Foot dragger singletracker

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    Several friends have had the Trail Tech Stator quit dead during long rides,kind of an all at once load you bike in a truck and go home sort of thing.
    Must both be flukes.

    I just keep it stock and run the bare minimum of electrical stuff,tiny LED taillight,Dirt Tricks Low draw fan,sometime a good LED headlight will be installed.
    #67
  8. LukasM

    LukasM Long timer

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    FYI that is not going to help stator life at all, if anything it will decrease it. A permanent magnet stator with a regular shunt regulator will run at full load all the time, and simply shunt the unused power to ground by converting it to heat, most of it through the regulator, but the stator will heat up as well.

    Solution is a 3 phase series regulator, but the few ones that are available are too big for use on an EXC.
    #68
  9. K_N_Fodder

    K_N_Fodder Long timer

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    Got it man, thanks! No drama yet, seems to work well. I was surprised that the light stays on for about 15 seconds after I shut down but Darryl at Cyclops said they have some kind of timer in there...

    For us no-knowledge direction-following types, the Trail Tech directions could use some serious work. The directions themselves are pretty good, it's making clear what set of directions actually apply to your installation that aren't wonderful. Hear that TT? :)

    J
    #69
  10. 211

    211 ThorsPadre

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    Wow... very nice thread! <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    Subaru, thanks for the diligent updates, including your results with the TT stator install. This kinda answers my question since I’m in the market to upgrade my Stator and ironically came across these Electrosport stators just this week.<o:p></o:p>

    Here’s why I think I need the upgrade. Last couple times I got caught in the dark still on the low rpm single track with my highbeams on I got out of the trail, shut the bike off to cool down and had no battery left to e-start. Once kick started and h/b turned off bike ran and charged normally. I also just picked up a TT X2 Halogen headlight which claims 70w (still in shipping so I haven’t plugged it in yet). It sounds to me like the stock stator wont keep up the highbeam at idle or low idle. However this issue will just compound if I drop in the 70w headlight.

    Later down the road I plan on installing heated grips and a fan override switch so I don’t have to wait till the engine gets to critical temps before the fans kick in.
    My question still is the TT stator. They claim 100-110w and the 70w light + 12w fan + 20ish-w grips doesn’t leave much room for anything else (led tail light, blinkers, optional gps/phone charger, heated vest etc…). <o:p></o:p>
    <o:p></o:p>
    Can anyone share results with the TT stator running lots of accessories? <o:p></o:p>
    #70
  11. Subaru297

    Subaru297 Been here awhile

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    Basically with the stock system you have three circuits off of the stator.
    1. Small amount of capacity dedicated to charging the battery. 30W
    2. Majority of the capacity is AC current and this runs the lights. 70-100W
    3. Ignition circuit. Separate coil that runs the bike (spark, cdi)

    I am not sure on the actual numbers anymore as I am going by memory.

    So no matter what you do with your headlight it won't change anything with your battery drain or charging ability. Your headlight will just be very dim at lower idle speeds and will brighten as your engine increases rpm if you increase its draw significantly.

    If you want better lighting you should look into getting some LED lights. These put out an amazing amount of light and don't draw much power. I think LED lights prefer DC power though.

    This is where the Trail Tech stator comes in. It gives you the regulator, stator and directions to convert the system over to all DC current. Now you would have two circuits.
    1. Ignition circuit, same as before.
    2. 100W charging circuit.

    You now have 100W going to the battery and any of your load gets pulled from the battery. So you can draw more than 100W as long as it is not consistently or for a long period as the battery will deplete.

    My current system;
    Low beam 10W LED
    High beam 65W halogen (soon to be replaced with 24W highbeam)
    Heated grips 30W
    Rad Fan 30-40W while running (??? guessing)
    GPS 5W
    Turn signals, brake lights, etc...

    If everything was running full blast I would kill my battery quickly drawing around 140W but that likely won't happen...ie. my rad fan and heated grips shouldn't be running at the same time. Nor do I ride at night a lot (high beam). But if I was ice racing, at night, in the cold...then maybe.

    I also have a LED voltmeter sitting on my dash so I always know my battery voltage. If it starts to drop or go too high I know something is wrong and I can fix it hopefully or turn something off.

    Another aspect of the TT stator is that is produces its full 100w right off idle. (So I was told by TT tech support!) this would be a good benefit for slow single track. The electrosport and the stock one need to get the rpm up a bit to generate peak power.

    I think you would be fine with all the accessories you want to have installed as long as you keep in mind the draw at any one time. Maybe you have to slow down and ride with your low beam while you have your heated vest cranked or something. Or go with LED lights....

    Low beam 10W
    High beam 24W
    Heated vest 30W
    Heated grips 25W

    89watts. Keeping in mind you will need some room to charge your battery but I think it is all manageable.

    Hope that helps and thanks for the thread compliments. I found little bits and pieces of info here and there but it was hard to find a good answer all in one spot.

    Cheers
    #71
  12. Honkey Cat

    Honkey Cat Tailights Fade!

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    Correct, i added led lights to stock 530 charging system, with a new battery the led lights on and riding for hour the battery was dead. Upgraded to the TT
    #72
  13. FOCKER

    FOCKER Northwest Adventure Rider

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    Eastern WA
    I'm glad I found this thread...Thanks for all the info. I'd like more details of your setup...Brands & Pix.

    I have a 2007 KTM 450XC that has the EXC KTM light kit installed. I'm sure it's a stock stator so I'm in the market for a TT. I found a used 100W for a $100 but it's older without the built in relay with a dedicated accessory wire (As it was explained to me). I sent 2 emails to TT today and had responses within minutes...Awesome service.

    My stock lighting sux and I'm going to have to upgrade but here's my intended use:
    Trail rides and camping off the bike...May get caught in the dark and need safe lighting.
    Commuting to work during the day but night street riding after 9-11PM.
    No long slab trips day or night.

    Darryl from CyclopsAdventureSports (He's been awesome) suggested the Orion Dual Sport X2 and a LED for emergency situations, using m stock stator for budget purposes. I'm starting to realize I may have to bite the bullet and upgrade. Still beats what you went through...Did you ever get your money back from electrosport?

    Thoughts?

    Oh...One more thing. I suck on the trails a stall and fall a lot...I may end up killing the battery with the E-Start.
    #73
  14. Subaru297

    Subaru297 Been here awhile

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    What would you like pictures of? The whole bike or something specific? I will have to get some tonight.

    As far as lighting goes, if you want to keep it cheap.....I would just get an extra LED light from ADVMonster or Mondo Motos. They are both in the vendor forum on here. Then you should convert your bike to all DC rather than the AC/DC system it is now.
    You will have to look that one up and it just involves some soldering/rewiring of your stock stator and a new regulator. I think the TT website has the parts and the instructions on how to do it.
    If you don't fancy that I would just get the whole kit from TT and be done with it.

    That light you referred to is the same as the Trailtech X2 but i wouldn't bother upgrading that. Just do the stator and the LED light and you will have more than enough light. Wire in a switch to disable your stock headlight and when you are trail riding and stopping and starting your bike alot you can turn off the light so it isn't also draining your battery.

    http://stores.homestead.com/hstrial-QualiRegResou/-strse-41/Model-60-LED-off/Detail.bok

    You should add a dimmer too if you want to use it on the street.

    http://stores.homestead.com/hstrial-QualiRegResou/-strse-LED-Controls/Categories.bok

    And yes Electrosport gave me a refund. They were helpful through the whole process and had good customer service but I either got a dud or it is just a poor design.....
    #74
  15. FOCKER

    FOCKER Northwest Adventure Rider

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    Your lighting but don't go out of your way to do so.

    That's what I'm thinking...Be done with it and never look back!

    I have the KTM euro switch and I can turn off my headlight now...So that's a bonus.

    Good to hear.

    Thank you so much for your time!
    #75
  16. Subaru297

    Subaru297 Been here awhile

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    If this was my intended use I would get the TT stator, and LED light, and keep the stock light for DOT purposes. I would also add heated grips and maybe an upgraded battery if the stock battery ever dies on you.
    If you are trail riding with the bike you don't want to add a bunch of extra stuff. Keep it simple!

    Cheers
    #76
  17. Subaru297

    Subaru297 Been here awhile

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    I have the Lynx Fairing on now so I am no longer stock. I just replaced the low beam with a 10 Watt led. The high beam is still the 65W halogen it came with. I would like to replace the high beam or add an LED light for night time riding but I haven't had to yet.

    Not my bike but I have the same fairing.
    [​IMG]
    #77
  18. FOCKER

    FOCKER Northwest Adventure Rider

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    That's what I'm thinking.

    I rode home from work just now and my new brackets I fabbed for the stock light plate helped a ton. If I had a LED as an accessory it would even be better on the darker streets.

    Here you can see my bracket which is adjustable plus notice the headlight sticks out from the plate. I added spacers behind the light which helped aim the beam on the road instead of the trees.
    [​IMG]

    I raised the fender mounts too.
    [​IMG]


    On a side note:
    This light looks awesome...But it's around $400-ish and not in my budget.<iframe src="//www.youtube.com/embed/s-bni1xWBMs" allowfullscreen="" width="560" frameborder="0" height="315"></iframe>
    <iframe src="//www.youtube.com/embed/3lHFzKpXsY8" allowfullscreen="" width="560" frameborder="0" height="315"></iframe>
    #78
  19. RideFreak

    RideFreak Torque Junkie

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    FOCKER,
    PMXTEC makes a replacment Halogen for that BA20 bulb you're running, Munn is a distributor for them but they only show 2008 and up. That BA20 is notorious for it's lack of vibration resistance and poor output (pretty much useless at night). The halogen is a big improvment, I put one in my 300XCW which has the stock stator and DS lighting and it's not caused any battery issues in the year it's been on the bike. It uses a small plastic adapter which allows you to buy replacment bulbs at the autoparts store but so far the supplied bulb has held up fine.

    #79
  20. FOCKER

    FOCKER Northwest Adventure Rider

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    Promising info...I'll look into it.
    Thanks
    #80