03 wr450 Charging problem
Posted April 08, 2004 - 02:09 PM
Posted April 08, 2004 - 04:13 PM
Posted April 09, 2004 - 04:26 PM
I also suspect the Baja Designs kit.
I am not an electrical expert by any means but....
I also purchased the kit for my wr450 and RETURNED IT.
The reason that you are having charging problems is due to the way the kit is designed!
Baja's Designs offers the kit with their standard handlebar turn signal switch. This standard switch is designed for DC current only (like the old XR's etc.)
However.... our WR's are both AC and DC like you said (as are the new KTM enduros I beleive.
For whatever reason Baja Designs has not yet re-thought this design.
I spoke with the guys at Baja a few times and was told that the WR's have a screwy wiring design and it causes regulator problems but it is only the bikes with the Baja kits that have this problem.
THE BAJA KIT IS THE PROBLEM.
By running your headlight and tail/brakelight on DC you are putting a huge load on that little battery and that poor regulator. It's a great little battery but not a car battery.
You are going through the same thing that I did 2-3 months ago.
DO A FEW SEARCHES (Baja, Dual sport, regulator, etc.)
You will find our discussions regarding this EXACT topic.
5spoke, NL7SC and the boys will back me up on this one.....
Send the kit back for a full refund like I did and tell them to let you know when they have designed one that works properly.
THEN, make a kit on your own. Yes, I am serious.
We'll help you. I was skeptical of doing it myself but it really isn't that hard and WAYYYY cheaper.
For the love of God leave your headlight on AC and use your stock bulb 55/60 (not a 35w !!! come on Baja!! not acceptable)
Replace the regulator/rectifier that the kit damaged, remove the Baja Designs kit and send it back to them for a refund. Tell them to talk to us on this site if they like. (they know what "Thumper Talk" is)
I/We will help you wire your own kit. I have all part numbers required and am glad to give you all the info that i have. K&S Brand parts are exactly what we need to wire our bikes the way they should be. The circuits on the handle bar switch are all separate and allow you to run the headlight (Hi/Low beam), tail/brakelight on AC and the horn and signals on DC.
Do search on our previous discussions you'll see.
I made a post asking everyone if they have blown regulators on stock bikes (with no Baja Kit) and there were NONE.
THE PROBLEM IS THE BAJA KIT. (Sorry to anyone that has one!)
It seems that the Baja Designs guys are telling you the same thing they told me.... LIES!
Do your bike right... Do it yourself.
How can we help dude?????????????????????
I hope this made sense..... Damn I'm still pissed at those guys.
Posted April 11, 2004 - 01:07 PM
Posted April 11, 2004 - 01:47 PM
Posted May 18, 2004 - 08:21 AM
With the light on the rev limiter kicks in, with the light off the thing runs great
Posted May 18, 2004 - 11:54 AM
I have not yet done this because i ride 95% of the time during the day and i just leave the headlight off.
I will look for it and post the directions.
Posted May 18, 2004 - 12:20 PM
I was very impressed with the ease of installation and instructions. It is a clean tight install.
Something to consider.
Posted May 18, 2004 - 02:02 PM
i have simply not used the headlight unless i have to. i have gotten instructions on this site about wiring the headlight to run directly off the AC side but have not tried it yet.
Posted May 19, 2004 - 11:18 AM
anyway, they have come up with a fix for this and it should be ready in a few weeks, they will be routing all power to a newly designed regulator that they claim will solve this problem.
they are suppossed to contact me when its ready and i will post it here!