New 300W KTM 640 Stator available

Discussion in 'Thumpers' started by overlandr, Mar 3, 2012.

  1. overlandr

    overlandr Dystopist

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    Having just read this post, thought it worthwhile to start a new thread as a heads up for any 640 owners who need more power. Its been on the market since at least last year. Should be a useful upgrade for those that need 300 watts or so.

    Here are details of the stator this is available:

    http://www.electrosport.com/stator-ktm-400-640-lc4-high-power-3-phase.html

    "ElectroSport developed ESG148 specifically for the KTM LC4 models. We manufacture it using the highest grade copper wire for the windings, superior stator lamination materials, high quality lead wires that can withstand chafing, and quality rubber seals.

    To improve dramatically on the output from the OEM stator we utilized a similar winding configuration as our ESG950 high power stator (for the YFZ660 Raptor ATV).

    The result is a very high quality product that offers about 50% more output than the stock stator. Thanks to the lower internal resistance our stator even runs cooler which makes it extremely reliable.

    All stators we manufacture come with a full one year warranty."

    [​IMG]

    $114
    #1
  2. Ol'Muley

    Ol'Muley old, not dead

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    Do you have to change the regulator also? Which one?Is the thin wiring up to the increased juice?
    #2
  3. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Any mention if the stock voltage regulator can handle the increased juice?

    A 100% plug and play juice-up would be grand for sure.

    Dirty
    #3
  4. overlandr

    overlandr Dystopist

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    I've just emailed them re fitting, regulators etc as I couldn't find their fitting instructions listed on their site. I'd say that the rectifier would have to be capable of handling the increased current.
    #4
  5. overlandr

    overlandr Dystopist

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    Just received this reply to my query with the suppliers which indicates its a straight swap over with the oem stator.

    Q:
    Hi, Re: ESG148, Would the rectifier need to be upgraded to handle the higher current? Do you have fitting instructions? Thanks ​

    A:
    No, the stock R/R is okay with this stator. So long as the R/R is in good shape it will be just fine.

    I dont have instructions for this one, but it is a direct plug in replacement. Just follow the instructions and specs in the service manual.

    Kyle Wood - Sales Manager
    -------------------------------------
    Procom Engineering / ElectroSport
    66 Maxwell, Irvine, CA 92618
    PH: (949) 748-6338
    www.electrosport.com
    #5
  6. Kirkster

    Kirkster Parts Murderer

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    Now we need to find out if this will bolt up to the 690.... It is an LC4 after all...

    K
    #6
  7. Kirkster

    Kirkster Parts Murderer

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    Sadly it won't work on the 690s. But they said that they should have one that does before the end of the year!!!
    #7
  8. gen

    gen Been here awhile

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    How much work is it to install this? I'd love 50% more power...
    #8
  9. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Gen-very easy.

    Remove the seat, the tank, the stator cover, and the stator from the cover.

    Follow the stator wiring bundle up to the top tube of the frame and disconnect the quick connect.

    Reinstall everything in the reverse order.

    You're done.

    Easy Peasy.

    I'd say it would take you right around an hour.

    Dirty
    #9
  10. gen

    gen Been here awhile

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    Thanks, D!

    I'm in on this bad boy.
    #10
  11. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Keep us all in the loop.

    From what I understand this is Electrosport's reconfigured ESG 950 stator which is the same exact size as Yamaha's Raptor 700 4 wheeler stator. I installed one of these stators on my '03 940A years back and used the KTM 950 voltage regulator. It was hardly plug and play.

    None of the electrical quick connects were the same, the voltage regulator was much larger, etc., etc....but it worked like a champ.

    This hopped up stator for the LC4 engines has the same quick connect as the OEM stator, AND they say the increase in power can still be handled by the OEM LC4 voltage regulator.

    It'll take you longer to remove the seat, the gas tank, and fish the wiring between the starter and the case than it will take you for the actual stator bolt up.

    I know alot of guys here are watching this thread, so let us know how it works out once you mount it up.

    Dirty
    #11
  12. gen

    gen Been here awhile

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    Has anyone installed this yet?
    #12
  13. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Hopefully the poor sot who installed this thing isn't dead for miles from nowhere having his eyes and entrails plucked out by vultures.

    I hate when those things come around!

    Dirty
    #13
  14. jrozar

    jrozar Been here awhile

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    I just pulled the trigger and ordered one, I am adding a set of Baja Desin Squadron Aux lights to the bike and needed some extra juice....I will let you guys know how it goes.

    It is 260 watts according to the person I spoke to when I placed my order.
    #14
  15. fastlane1

    fastlane1 Catching up with my past

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    I installed one on my 640 Adventure. It works great and is plug and play easy to install - note that my regulator does get pretty hot with this. Attached photos show old damaged stator and the new one. Old stator was damaged by a broken tooth from my intermediate gear. Note that the new stator was very well packaged but on opening I noted it was damaged (see the cracks). I called supplier and they said that should still be OK and it is.
    #15
  16. gen

    gen Been here awhile

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    "Sorry, that page was not found."
    #16
  17. fastlane1

    fastlane1 Catching up with my past

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    Photo link is here
    #17
  18. jrozar

    jrozar Been here awhile

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    I'm getting ready to get mine installed on my 640 Adventure, I will need to support 162 watts of additional lights.

    I'm adding two Vision X Optimus 4" as headlights


    One Baja Designs 8" Onx light bar


    Two Baja designs Squadrons.


    This combination should get me around 16,000 lumen
    #18
  19. Kawidad

    Kawidad Long timer

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    It would seem to me the hot ticket a new Shinden (sp?) regulator and get rid of the hokey capacitor, since electrically it isn't necessary. Although, it might need some new/rewiring to accomplish this set up. :evil
    #19
  20. Guardsman

    Guardsman Iron Horse Farms

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    Is a new regulator/rectifier required with the upgraded stator? Would it be recommended for an extended (month +) trip? I have a 2003 ADV with 12K miles on it that I am working the bugs out of...

    Thanks
    #20