XR650R electricity

Discussion in 'Thumpers' started by themansfield, Jan 8, 2009.

  1. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA
    Zenmoto, your discription gets a little confusing but you've got it right, the AC reg gets wired in parallel with the light. If it's working properly the headlight will stop getting brighter at about 4000 rpm.
    #41
  2. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,467
    Location:
    Beaverton, OR

    That'll do it. A DC regulator/rectifier won't work properly without some sort of energy storage on the DC side- either a battery or capacitor. It will output a series of narrow +12V pulses instead of a steady voltage, so the average voltage will be way too low. A good sign of this happening is that the voltage is higher at idle than at high rpm.
    #42
  3. ZenMoto

    ZenMoto Bikeslut

    Joined:
    Jun 30, 2005
    Oddometer:
    685
    Location:
    Moorpark, CA.
    Thanks again guys. Just got out of the garage and I'm a happy camper (mostly). ...I forgot that the computer is still wired into the AC side, but has a frame ground still, so (maybe this is the reason) it's still not getting power from the bike. I don't care enough to tear it apart again right now. I'll deal with it next oil change. :)

    The light, however, works like a charm! Nice, bright, steady light!

    With the exception of the light on the one AC side, the rest of the system is very un-taxed, despite the fact that I'm running everything else on the bike from the DC side, including heated grips. Switching to LED turn signals and for the brake/tail light pays off big time both in power consumption, and durability on the trail. :evil

    Thanks again for the help and feedback. I'm going to head up to Gorman tomorrow morning for a shakedown run if any of you LA locals want to come out and kick knobbies! :lol3

    Thanks again, Cheers!!! :freaky

    Dale
    #43
  4. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA
    Good job Zenmoto, I love it when a plan comes together. If the mood strikes you, post a pic of the pig.
    #44
  5. ZenMoto

    ZenMoto Bikeslut

    Joined:
    Jun 30, 2005
    Oddometer:
    685
    Location:
    Moorpark, CA.
    I took some photos of it clean, after getting the wiring done and buttoning her back up. ...and got some more today while out riding, so the pig is good and coated in dirt & mud (as pigs seem to enjoy). :)

    I've decided to name the beast BBQ (the pictures will make the reason clear).

    I'll try to get the pics posted tomorrow, and I'll dump them into a new thread. :)

    Thanks again for all the help. The shakedown proved out that the light is working fine! :freaky
    #45
  6. themansfield

    themansfield Adventurer

    Joined:
    Jan 5, 2009
    Oddometer:
    83
    Location:
    San Diego
    Ok, here's one.

    Bike currently runs dual sport kit on DC alone.

    Can I install the BD rewound stator, re-install the stock AC reg, and somehow use the DSK handlebar switch to control the headlight and brights on the AC side?

    --Toasted that little DSK battery this weekend by running headlights and cooling fan together on stock stator output. Blasting down a desert highway on a moonless night with what was as good as a match in a tin can was certainly not the safest thing I've ever done.
    #46
  7. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA

    What you want to do is the same as what I have already done on my bike. PM me your email address and I'll send you the schematic that shows you how to hook it up.
    #47
  8. Irnworker433

    Irnworker433 XR650RRRRRRRR

    Joined:
    Oct 12, 2008
    Oddometer:
    98
    Location:
    Fleischmanns NY
    Well, I had the opportunity for LEX (XRIDER) to do some electrical work on my lil "piggy" (02 xr650r) this past week. I cant tell you guys enuf how good of a job he did with everything. I highly recommend his services if you are anywhere close to the Bay Area Calif. He's got one bad assed xr650r that he super moto'd out to the hilt. Im jealous! Anyways cant wait to try out my new Baja Designs 8" in. Halogen in the Desert very soon. Ill send yall some pics after the maiden voyage. YAY!

    Jackrabbits MC RULES! District 37!
    #48
  9. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA
    Thanks for the props.
    #49
  10. Desk Jockey

    Desk Jockey Adventurer

    Joined:
    Feb 13, 2009
    Oddometer:
    81
    Location:
    California
    xrider, i'd like to take you up on your offer of schematics--and then maybe persuade you to take a peek at my rat's nest of a wiring job on my 02 XR650r (w/ ricky stator, dual sport kit. maybe joe racer? baja d? not certain).

    anyway, i've got 8, count 'em, 8 wires coming out of my stator. i've got 2 green ones, 2 white ones, and the 4 multi-color. one green and one white go to the regulator/rectifier. the other green and the other white go nowhere. i'm thinking this pair is the other half of my 200w ricky stator just waiting to be used as AC power in the future?

    the regulator/rectifier itself has 4 short wires, 2 of which are connected to the aforementioned green & white from the stator. the other two are black and red, and the rectifier itself has a diagram on its side showing red and black going to the battery -- and to "LOAD". a few splices here, splices there, double fused this, taped up that, and red does go to the battery eventually, and also to a white wire (whose tiny letters say "ground"). This white wire then runs parallel to three other wires all the way up to the headlight area. This must be my "kit". Stock kit or aftermarket kit, I'm not sure. The black wire also goes to the battery, after going through a ground, and also to and from a kill/power/toggle switch rigged into the rear fender. when the switch is off, lights are off and bike won't start. when switch is on, lights and signals and horn all work and bike can be kick started.

    But then i've also got the 4 multi-color wires from the stator connecting in ones, twos, and threes to all kinds of other wires in crazy ways, some to a "Denso" card-deck sized box (my CDI?) where it splits again and a wrapped bundle goes toward the headlight area. i believe a green and a black/yellow wire split out of this bundle and into a black doohickey and then on to the spark plug. nice. i get it. still not sure what to make of all the other wires that seem to have no connection at all. Or do they, somewhere under the wraps?

    dismounting the headlight, i've got about 30 wires under there. nuts! it's like i have two or three full kits on there or something. anyway, i'm enjoying learning something new and following where all these go. long winded way of saying, "Please!"
    #50
  11. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA

    Aaaaahhhhhhhhhhhh.......Run away!

    Just kidding, let's start by PMing me your email address so I can send you the schematics as an attachment. Are you located anyware near my shop?
    #51
  12. azcagiva

    azcagiva new orange flavor

    Joined:
    Apr 23, 2007
    Oddometer:
    1,173
    Location:
    Camp Verde, AZ
    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.
    [​IMG]

    [​IMG]

    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
    #52
  13. Gyroaxle

    Gyroaxle Banned

    Joined:
    Mar 3, 2009
    Oddometer:
    44
    Location:
    NW of "Ya-Po-Ah"
    __________________________________________________________________


    Ha! reminds me of a 1960 VW I had, with a 6 volt charging system, I called its headlights - "Two Candle Power" :rofl
    #53
  14. joenuclear

    joenuclear Ride to eat, eat to ride... all roads lead to pie!

    Joined:
    Mar 16, 2007
    Oddometer:
    7,425
    Location:
    Fort Smith, Arkansas
    It looks good. Lets us know if you have any problems with the subframe or tire clearance issues.:ear
    #54
  15. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA
    I'd say your battery installation looks pretty sharp. It's tough to find enough room to mount a battery that size. If it doesn't hit the tire I'd say you're golden.
    #55
  16. arrcrussell

    arrcrussell Gimme Dirt

    Joined:
    Sep 8, 2005
    Oddometer:
    918
    Location:
    NE OH, USA
    Pipeline, Allegheny NF, PA. That's a buddy's XR400 - honestly, no BS, I'm not kiddin, really - We all bust his balls cause he buried it in a sinkhole in a 50ft long 4x4 rut and when asked why he went thru it he said - "Well, it was flat on top!"
    #56
  17. XRider

    XRider Almost Lifelike

    Joined:
    Oct 11, 2006
    Oddometer:
    1,295
    Location:
    Los Gatos, CA
    The funnest thing I ever saw was when a buddy tried to ride across a dry (but muddy) pond. Hits the middle and the bike sinks up to the pegs in the mud. Steps off the bike, sinks up to his knees in the mud. Trying to walk through the sucking mud he gets one step off before he loses his balance and falls forward. He put his hands out to break his fall and his arms disappeared and sunk into the mud up to his sholders. He is screaming for us to help him but we are laughing so hard we can't do anything. Luckely he still had his helmet on or he would have drowned in the mud. It eventualy took two 4x4 quads chained together to pull the bike out.
    #57
  18. azcagiva

    azcagiva new orange flavor

    Joined:
    Apr 23, 2007
    Oddometer:
    1,173
    Location:
    Camp Verde, AZ
    I just finished getting most of my parts together to build my 70w HID. I am still waiting on a stator cover gasket.

    I built this ring this evening to hold my big reflector. I had a friend of mine cut the ring for me out of 3/16" steel, all I had to do was weld on the tabs. I still have to paint it and drill a hole to mount the big knob for the head light adjustment. The ballast will be mounted on the top of the cage. Trail tech wanted too much for their light so I went with the Baja Designs one instead.
    [​IMG]

    This is the reflector in the BD cage.
    [​IMG]

    [​IMG]

    [​IMG]

    Once I get the stator cover gasket I can start on the wiring. XRider has been nice enough to offer some help with the wiring.

    I will post more pics as the build progresses.

    -John
    #58
  19. azcagiva

    azcagiva new orange flavor

    Joined:
    Apr 23, 2007
    Oddometer:
    1,173
    Location:
    Camp Verde, AZ
    Here is the light mounted on the bike.
    [​IMG]

    It looks like I have room to mount the ballast under the light using the holes that the stock light used. Now all I need is the stator cover gasket and I can pull the tank and start wiring.

    -John
    #59
  20. winterhk

    winterhk *Disminuya Su Velocidad*

    Joined:
    Dec 16, 2004
    Oddometer:
    2,318
    Location:
    Cape Coral, FL
    John,

    That's gorgeous man! Hope you're taking notes, because I'm going to need you to do the same for mine! :lol3 Those 70W KCs are off the hook.
    #60