This is a follow up to a previous post that was nuked during the TT Website update.

To recap I bought a Tusk dual sport kit from Rocky Mountain MC/ATV for my 02 300 EXC that uses a battery to power the led tail light and blinkers, but the head light still uses power from the bike.

Since I didn't need the OE tail light/rear brake light wiring I removed it. Once I got it all put together I noticed the head light did not work anymore. Mind you this bike has been run hard and put away wet so the condition of the OE wiring harness is not what I would call ideal.

I tried connecting the leads to the rear to close the circuit and still no luck. I then checked the voltage coming from the stator to the regulator and found that one wire (white) had plenty of power while the other, (yellow) wire (my guess the return) was very low. Both of these leads feed into the voltage regulator and from there wires go to the headlight. My guess is the voltage regulator is shot. Any tholughts on this. I'm pretty good with mechanical things but have limited knowledge of electrical systems. I don't want to spend $50 bucks on a regualtor only to find that its not the probelm. Thanks!

The stator produces AC power (unregulated). The reg/rec rectifies the AC to DC and regulates it. When you start the bike you should see AC power on both the white and yellow from the stator that will spike when you rev the engine. The output of the reg/rec should be a steady DC voltage. With a volt meter you can easily verify if the stator and reg/rec is working right.
Joe...........

Also, here is some good info: http://www.omraoffro...hp?f=40&t=10564
Joe.......

JoeMcLaughlin, on 28 January 2012 - 03:45 PM, said:

Thanks

That's exactly what I see from the leads coming from the stator. I have AC power on the yellow and white all though the white seemed like it has more voltage. I checked both DC and AC comming from reg/rec and had no reading whatsover. I guess its toast. Its odd the headlight was reciving power just before I installed the dual sport kit. I can't think of anything I've done that would cause the reg/rec to go bad..

JoeMcLaughlin, on 28 January 2012 - 03:50 PM, said:

great info, thanks!

There are a few different ways you can go and I am not sure what config you are using. This may help: http://www.trailtech.../010-ELV-71.pdf
That is the way I set my bikes up. The ground is floated with a battery in the air box. Also, this may help: http://trailtech.net..._rectifier.html

Here is yet another reference: http://www.tripleate...2003Wiring1.jpg

Joe.......

Thanks for all the help I have finally fixed the problem.

Apparently the switch and some of the connections were FUBAR. I spent a bit of time going through wiring this evening just to make sure before I dropped coin on a rectifier. After cleaning everything and properly attaching all the wiring spade connections everything now works. I did find out interestingly that the KTM300EXC 02 model powers all its lighting on AC. Only the coil gets converted to DC. That means I'll never be able to use one wiring system unless I change the coil, headlight and or the rectifier. Even though it’s plated I think I'll continue to run the boot leg headlight. I'm only planning to cross roads to connect trails with this bike and take it on OHVs connected by Forest Service Roads.

Not exactly. I am not sure by what you mean when you talk about the coil? Don't confuse your ignition with lighting. You have a 2k3 stator with two AC outputs from the stator that have nothing to do with ignition and you can rectify one or both to DC or one to DC with the other AC, you get the idea. A simple halogen light can use AC or DC while HID needs DC. I hear there are LEDs that can run off AC but I have not played with them yet.

Anyway, glad you are back up and running;)
Joe.......

T30, I am thinking about using the tusk kit dual sport kit for my xc-w. Can you comment on the quality, installation, would you go this route again? Do you have you headlight set up with high and low beem? thanks, glad you fixed your bike.

shoein, on 02 February 2012 - 03:54 AM, said:

Everything seems to work. Installation is easy. The only kicker is the headlight. I elected to use the OE headlight so I can't use the multi control to work it. The OE headlight does not have hi and low beam. That set up is really not compliant but it will work for my very limited road use when connecting trails. If you want to go all the way with a legit set up you will need to change your electrical system to feed DC to the battery since the OE lighting is all AC. I basically running 2 circuits. One DC run by the Tusk battery(blinkers tail light and horn). The other AC (headlight only). All in all if you don't want to spend much the Tusk is fine, but don't use it to commute on the roads because it won't pass muster. I paid about $205.00 for the whole thing.

Thanks t30. If I can figure out how to get a high and low beam then the tusk kit may be an inexpensive way to be legal.