www.bajadesigns.com/products/turn-signal-standard-pair.asp Looks like I have the STATOR BD Rewound on it. www.bajadesigns.com/products/stator-rewind-honda-xr650r.asp I want to put a road approval kit on it. It already has a flagship Baja Designs. 4) www.bajadesigns.com/docs/tech-info/xr650r-dual-output-rewind—no-dual-sport-kit.pdf?sfvrsn=4 www.bajadesigns.com/products/switch-handlebar-control-dual-sport-kit-2011.asp 1) www.bajadesigns.com/tech-info/dual-sport-kit-faq 2) www.bajadesigns.com/docs/tech-info/installation-instructions-for-rewound-stator-on-xr650r-with-quick-release-dual-sport-kit.pdf?sfvrsn=4 BD used to insert a large toggle switch into a top Mounted The metal bracket is triple as a submarine for the OEM key switch and keeps all OEM kill switches in OEM controllers as they have the XFL. The battery was there to meet the CERTIFICATION AUTHORITY`s requirement that the bike can display lights for 10 minutes when the bike is not working. They used 8 NiCads AA and packed them. my memory sez there were two generations of XR straps – I think yours is Gen2. I`ve removed the diagrams if you can`t find them on the website – I know some things were really hard to access some time ago as they downplay their road approval kits. LMK and I can dig them up and send them your way if Ness. So, at this point, I would like to ask: What do I need to fill out the road approval package? I could buy the Tusk, but since it`s already partially there, it looks like I could buy the rest of Baja Designs.
I don`t know what the stator is there, whether it`s a stock or an updated stator. Probably also a sinuous stator. You can pull the lid of the stator towards. Fast work of 5 minutes because there is no oil in it. When all the stems are covered, it is rewound. You already have most of the Baja Designs double sports kits, only a few elements are missing. If you have a burning desire to know if the stator is rewound or reworked, remove the stator cover and note how many coil windings are now involved in the output. In general, the wires coming out of the stator case indicate whether the stator is standard or rewound, which avoids the hassle of removing the stator cover. However, keep in mind that there are some who rewind their own stator, which could confuse the wiring diagram and color coding.
If you don`t suspect any rewinding or strange wiring yet, start by identifying the standard wires and color coding that should be. And check the continuity and voltage of the battery. Personally, I would simply add turn signals, signal relays, a horn and a handlebar switch to the existing wiring harness. As I said, the wiring seems to be in good condition. Either it`s a modified double BD sports harness, or someone has built their own harness from BD parts. It looks like they did a very good job. It is properly fused, the wires have shrunk hot and these blue connectors are good posi-lock units. ADDRESS: 6944 Santa Fe East, Hesperia, CA 92345 PHONE: 760-244-2626 FAX: 760-948-0979 EMAIL: | order | Social Service Shipping: blog | | Facebook`s Instagram switch could potentially be a kill switch (I can`t see if you have a separate one) or for traffic lights. Thank you for your helpful answer.
I appreciate it very much. I`ll check the stator this weekend and get back to you. Looks like I need a wiring harness, doesn`t it?. Also, you`re concerned about the stator and wiring, as well as whether the stator has been rewound for superior performance. Since this is a non-dual sport before you owned it, the only incentive for higher performance would be extra lighting. Or maybe the cycle once had a conversion kit? I noticed the DENSO 070000-2840 QAC84 component, but from the research I`ve done, it`s a CDI. I guess it is a stock. I removed the guards and the seat and took the photos below: Question 3: On one of the photos, a connection spits out and a leash is opened. Can this be used for wiring in a horn and traffic lights that I still have to buy? Green and white go to the standard AC controller. Green/white and light blue go to the wiring harness and connect with a green wire (green/white) and a dark blue/white wire (light blue). No matter how I connected the wires, I don`t have lights or horns. I think the battery of the Baja kit may be empty, but it`s hard to say.
I tested it with a test light and didn`t get anything. I suspect the battery is empty since I only received the kit a day or two ago, but who knows? I can`t find a better reason why absolutely nothing works. In any case, the staff at Baja Designs is very knowledgeable and ready to help you if you can`t get through this problem. In the meantime, to give you some reading material and maybe an overview or fact you need, here are four PDFs from the Baja Designs library: Question 4: The on/off switch is something I didn`t understand. I turned it on and off and I don`t notice any difference in lighting. Is this change in stock? You must be a member to leave a comment. Read these PDFs that I`ve done more than once, and if nothing else, you`ll be at the top of the learning curve of the XR650R dual sport kits and wonder if you need a stator feedback. If you don`t have a high-draft headlamp and are using the standard watt Hi-Lo lamp that comes with the Baja Designs Basic kit, I can confirm that the standard stator is sufficient. When increasing the power of the headlight, lean into the area of a rewind for the stator.
My dad and I connected everything to the Baja Designs kit and removed what was left of the other kit. Thank you in advance. This forum has been very useful to me so far, but this is the first time I have signed up and made a post. Best wishes! Stator Modifications: Baja Designs offers a modification of the stator (Ground Float), which we do for you at an additional cost of $30.00. If you want to make this change yourself, we have given you detailed instructions on how to do it yourself. At this point, we don`t know how to connect the BD harness to the stator harness. An idea where we can find a diagram or an image of it? Welcome to the forums, ripatte, let`s put the XR650R in dual-sport operational mode! I see you have a battery and a shared AC/DC system. The metal box next to the DC controller/rectifier is an AC controller. Baja Designs` contact phone number ((760) 560-BAJA (2252) can put you in touch with helpful staff. The hours are Pacific Time from 8:30 am to 5:30 pm, I called Pacific Time in the morning or afternoon for best results.
Call with as much information as possible and the staff can help you find a solution quickly. Any ideas? I`m lost. As I said, I bought the used bike, so I don`t know the story, but it seems that the stator has been rewound, but I can`t find any reference to these colorful threads on the Internet. Looks like we`re going to be in the troubleshooting phase for a while. Here is a picture of the wires coming out of the wiring harness. I don`t know if this harness is standard, if the stator is completely DC, or if any part of it comes from the previous kit. As you can see, there seems to be a Baja Designs regulator and rectifier. Question 2: I know one of the boxes is the regulator/rectifier, but what about the component right next to it (has a metal casing and screw on it, which is all you can see)?. My father and I worked on setting up the double sports kit. I found a complete Dual Sport BD kit on eBay and bought it. Our OEM parts department provides complete assembly diagrams and parts lists for all Honda, Kawasaki, BRP, BMW, Kymco, Ducati, Polaris, Suzuki and Yamaha motorcycles, ATVs, personal watercraft, snowmobiles and off-road motorcycles.
We offer a wide range of hard parts, apparel and accessories for all types of motorsports vehicles, including sports bikes, cruisers, off-road motorcycles, ATVs and ATVs. We pride ourselves on our exceptional personalized customer service. Not only do we list the parts for sale, but we know all the products we sell and can help you find everything you are looking for. We are always here to help. The 2 white wires that come from the stator and are not included in the diagram you displayed should go to the two yellow wires of your spare Baja design regulator/rectifier, and from there you can power your headlight and charge the battery installed in the aftermarket and other things. The Baja Designs Kit uses the OEM reg/rec and also uses a high-end version of BD as well as two separate circuits when you come from this stator. Two separate 125W power sources. If you just want to power the small low OEM headlight, you can just use half of the stator and finish those extra 2 white wires of the stator and not use them and run everything from the first 6 stator wires with the OEM reg/rec installed with that single bolt at the top of the airbox. It depends on your experience and how comfortable you feel doing it yourself. If that were the case, I would simply add them.
The wiring appears to be in good condition. You can download the diagram from the BD website. Thank you in advance for your help. It is very much appreciated. A Google search led me to the attached table showing only 6 of the 8 threads coming out of the stator. The two white threads in the image are not shown on the diagram. Are they two dead sons? Or do they refer to the lighthouse? The instructions state that the white wires from the stator must be connected to the orange and white wires of the Baja Design Dual Sports harness. Since no two white wires come from the stator, I connected the green/white wire and the blue wire with the orange and white wire. When I do that, the bike doesn`t start. I guess this is because no energy flows from the stator to the coil on the green and dark blue/white wires in the wiring harness.
I don`t know exactly, but when I reconnect the stator wires to the green and dark blue/white wires, the bike starts with the second or third kick. I even plugged in the key to the Baja Designs kit so that it kills the engine when it`s off and allows it to start that way when it`s on.