Night terrors with DS kit.
Posted July 14, 2006 - 11:07 PM
Posted July 15, 2006 - 03:51 AM
You won't have to modify much at all to install the Ricky Stator. Recall, it has 2 coils. One of the coils will hook into your regulator/rectifier (just like your stock coil) and drive your dual sport kit. You could actually stop here if you wanted, and you would have roughly 2x the output that you have now, and your DSK will function just as it does now. The other coil just wouldn't be used.
Later, or whenever, you can add a small regulator, like the stock one, or you can buy a heftier one from Ricky Stator. Then you will unhook your headlight from the DSK and hook it up to the new regulator ->2nd lighting coil. Now, this will make it so that you headlight runs on AC (rather than the DC system on your DSK), right off the stator, such that your headlight will ONLY work when the bike is running. Here, the headlight has it's own output all to itself. You could upgrade your bulb to 55/60W or even 100W if you wanted without affecting the charge to your battery on the DC DSK side.
Your DSK handlebar switch will no longer control your headlight. You can hook up a new switch so that you can actuate the HI/LO beam on your headlight. Or you can use a relay. This gets a bit more complicated, and deserves it's own discussion by itself.
These extra regulators and stuff will start taking up alot of extra room that you don't have. This is why I opted to wind my own and stick with a single large coil. My dual headlights are 55W single filament (no HI/LO beam) so no need for a switch or relay, they are just ON, and cars see me coming a mile away. They are aimed down enough so that cars don't flash me at night. There are benefits and disadvantages to single vs. dual coils, so to each his own.
some pics of my dually headlights, quality isn't so good...
Posted July 15, 2006 - 04:20 AM
If you want "insurance", try to find another stock stator on Ebay (I don't see any right now). Keep your stock one as is and wind the other one. But really, it's not that hard, you only have one coil, with two ends to deal with, and it doesn't even matter which one goes where. All you need is the 18awg wire, epoxy and a cheap soldering iron and solder and a bit of patience. Let me know...
Posted July 15, 2006 - 08:51 AM
Posted July 15, 2006 - 02:20 PM
Now here is where there is a little difference.
Dual vs single output;
Rickystator and a Baja Designs rewound stator is Dual output (Could be made single but why?) but Dual means it has 2 x 100w, but for a Baja Designs DSK that orginally had a single output stock stator you will have to get or make a part that they wire together which is a Relay and regulator/rectifyer to switch between the two outputs or combine them for highbeam with Running lights (I believe it was $11 w/ DSK purchase). I'm not 100% sure b/c I haven't examined it too well and I just got it on last week but I believe it has 1x100w output goes dedicated to headlight in High beams and the other 1x100w goes to the rest of the DSK and regular beams/running lights. How this is benificial...I'm no electrical engineer but I assume that its better than 200w full time everywhere?
So in your situation. Battery should charge with 35w output. Maybe the previous owner had too large of a bulb when he got his DSK b/c it draws more than the stator can supply and draws off the battery in addition.
a) You can rewind your stator and see if that helps with the demand for power.
Replace battery and see if the old one wasn't taking a charge. I'm sure Baja designs can tell you how to test if it is charging correctly.
c) send in your stator for baja designs and let them wind it but Rickystator didn't require the stator and you could ride until it arrived...(I DON"T REMEBER PRICE) and they will ask you Dual or Single output (Single just combines both leads for 2 windings in one connector so could be seperated if you needed) But if you got it from baja designs maybe they could throw-in the relay/regulator/rectifyer at a discount if it is more than I quoted. (Have to call and wheel and deal)
I know you didn't ask but incase you were wondering why I went Rickystator after rewinding my own...
1) b/c Before I just had a headlight and an 55W bulb. I knew that I could wind my own and get it close enough to power it alone, b/c it wasn't anywhere near what the output was supposed to accomplish incase I didn't use the same gauge wire, didn't have enough winds somewhere etc. Or if I just plain messed it up. No loss. Now I was going on the street I needed a known output to charge the battery and run the equipment at the same time.
2) when I decided to drop the money on the DSK I knew what size bulb I was getting and the output that was recommended and I liked the idea of putting a new high-output stator in with the other new components for the DSK.
3) Myself I had some electrical issues in the past that ended up being minor loose wires or connections but in diagnosing the problem Since I had a Stator that I rewound Everyone I talked to wanted to blame it once they heard that I rewound it. (IT never was the problem) I couldn't get anyone at my dealer/ or online Tech support to give ideas other than it b/c they had no idea of my quality of work. (I didn't either b/c I had never done it before) But it worked for 3 years and worked till I took it off
4) it was single output and the BajaDesigns salesman talked me into needing dual output over single...(I may have gotten dupped when it cost me $11 for their part and the Price of the stator I didn't buy from them)
Ok that is my opinion and nothing but, (Maybe a load of BS)
Posted July 15, 2006 - 10:56 PM
Posted July 16, 2006 - 02:30 PM
If I am understanding your question, not exactally.
Was the extra part you got from BD just a way to separate the headlight from the rest of the DSK wiring harness?
Its a way of feeding in 2 seperate outputs as you understand but the are fed in as follows.
One output (100w of 200w) goes to DSK AND low beam-Headlight b/c 100w is ample. B/c DSK doesn't require that much so while running running off of stator only AND charging Battery.
2nd output goes to bright light so when you switch on the bright light and have a 100w bulb like I do it has 100w of dedicated power for it (which means less dimming at idle b/c the rest of the kit isn't drawing off of it).
The "Part" is a relay which when powered by the Bright light switch allows the 2nd 100w from a second regulator into the headlight. Someone could probably tell you how to make one. I didn't pay close enough attention b/c they had it wired in to my kit when it arrived so I didn't have to concern with it so I'd have to break down the wire loomb to see how it is wired in.
If you rewound your own and had a Single output you would have it hooked in as it is now. It would mean that you have 200w regulated to your entire DSK which ultimately totals near the same but that just means that when you do have a load on it it will draw from the entire system instead of just one output. So more constant power with dual output.
Again not 100% necessary, you'll have to decide for yourself. I'd recommend calling Baja Designs b/c they are the makers of your DSK kit and ask them EXACTLY what it does, and if you needed or could benifit from it b/c I'm not an expert I'm just deducting from where I hooked it all up.
It was $10-11 for me to run as dual output over single and it was recommended since I am running a 90/100w bulb.
When you ran your own rewound stator did you just hook it up like it was originally?
I rewound mine back in 2001, I don't know when it was changed.
Did you rewind your stator using the original directions or did you rewind all 10 poles with 18awg, 32-34 wraps per the updated guidelines?
I did rewind all the coils and I did coun't the wraps so I'd do them all the same but I don't think it had a specific number. As far as the gauge of the wire it was 16 or 18 too long ago to remember. I still have some wire but I can't tell by looking....The old instructions said to hook the outputs up wrong but it didnt' make sense to me so I didn't do it that way and I hooked it up the way the updated version says.
You will benifit from a rewound stator (Whether you do it or buy one) even if it is the battery b/c it will also mean more power at lower RPM's So brighter light at slower speads such as tight woods riding! I assume it means faster charging of battery on shorter trips as well.
If you trust yourself, have the down time with your bike, and can justify the cost rewind your own. I thought it cost $30 in parts at the time. Maybe someone can even tell you how to wire up a dual output? It certainly can't be anymore difficult!
Just my opinion!
Posted July 16, 2006 - 08:55 PM
Posted July 16, 2006 - 09:22 PM
Thanks as well for the input. I think my primary problem is an old battery that has not been fully charged as after just a 10 min. ride I could run the lights for awhile with the engine off.
Just a word of caution. I have a BD DS kit on my R.. it's great, but the
connecters suck. I have replaced the connector between the stator and the
stock wiring, it melted itself (bad / loose connection)
I have also replaced the connectors to the battery (just he yellow wires)
they were poorly attached to the wires and often caused an disconnect of
the charging system, which would cause the battery to run dry.
Since replacing there connectors everything has been fine.
Get yourself a circut tester and check the connectors out.
Posted July 16, 2006 - 09:34 PM
Posted July 17, 2006 - 07:15 AM
Man, once again I appreciate the time you've spent answering my question. I guess I've nothing to lose if I try to rewind my stock stator. If It does not do what I want I'll just buy the Ricky stator. I'm not looking for hard core lighting that will offend in traffic as I will be using the bike to commute alot. Just want to have enough output to run the DS kit without depending on the battery & have just enough left over for some hand warmers. One thing I did not do is check the wattage of the buld in the headlight. The gut I bought the bike from had a new headlight element in the package which I assumed was same as original. All was well until the headlight was on at night. I'll get to work. Thanks again!
Snaggle is great but I may have missed something. Ill add my 2 cebts, if you go with a new battery from batteries plus, the 2.9ah gel cel the BD system, and you got the rectifire/regulator you will not have a problem. But like snaggle said, you really need to up-grade your stator. Do it right and but the ricky stator as you have the stocker for backup-forsale. And you run it in dual output mode running the headlights (up to 100 watts!) on one side and the rest of the bikes electrical system on the other 100w output. On the second output which goes thru your rec/reg you get fairly clean 12-14VDC out of so you can run any accessories you run in a car off that output.
Posted July 17, 2006 - 07:40 AM
Find out what wattage (volts X amps) or just amps that the grip heater system you have will use. Also, see if you can find out what wattage bulb you are currently using, and what wattage bulb you want to use. This will make things easier...
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