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rhythmofbeing

650R dual sport electrical gremlins

4 posts in this topic

This new-to-me bike has a rewound (dual-output) stator and what I think is a BD dualsport kit. However, the electrical system is running at a very low output--the headlight is worthless in the dark and battery eliminator isn't charging. However, a couple nights ago when I started it up, it was really bright for about 30 seconds, then dropped back to low power.

I haven't dived into the wires with a multimeter yet, but I was wondering if there are any 650R-specific gremlins to look for, like floating versus normal ground.

Thoughts?

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This new-to-me bike has a rewound (dual-output) stator and what I think is a BD dualsport kit. However, the electrical system is running at a very low output--the headlight is worthless in the dark and battery eliminator isn't charging. However, a couple nights ago when I started it up, it was really bright for about 30 seconds, then dropped back to low power.

I haven't dived into the wires with a multimeter yet, but I was wondering if there are any 650R-specific gremlins to look for, like floating versus normal ground.

Thoughts?

If in fact you do have a BD's kit, You could go to the BD's web site for trouble shooting. If the previous owner installed a BD's kit, he may have had them do the stator as well. Good luck...:thumbsup:

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BD has very good information for the wiring on their site. You need to download the pdf files for the DS installation instructions. They have wiring diagrams in them. You can also see the wiring diagrams for the HID lighting systems, as they will be very similar (dual output stators).

For the record, I had an aftermarket high power stator (Moose) and could never get it to work quite right. My riding partner had his 650R stator rewound by BD and never had a problem. We had them wired identical, as they both had identical wires coming out of them. Mine just worked sporadically. I sent a spare OEM stator to BD to have it rewound, and all of my lighting problems were eliminated (I run a Trail Tech 8" HID race light).

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What eastreich said.

I did my own stator rewind. Single output, going through a ProCycle regulator-rectifier. To futher smooth the voltage I send it through a small 1.3 amp-hour sealed battery, to power my gps and other tricks.

There's no easy way to shoot your trouble except just roll up your sleeves, get your multimeter, start at the headlight and work backwards.

My only other suggestion is at some point pull the stator cover and carefully check the routing of the wires to make sure there's nothing funky going on with wires shorting out or whatever.

One mistake I made when I went to wire-up and install my rewound stator, was I forgot that the copper wire I used had a clear epoxy coating that needed to be scraped away before I soldered up the connection.

Point is, with an electrical gremlin you gotta check everything. Assume nothing.

My guess is its either a bad connector somewhere between the headlight and stator, or a 12v lead is momentarily shorting to ground somewhere.

You said your stator is dual-output. Do you have both outputs going to the headlight or only one, and the other output leads power the rest of the DS lighting?

Sorry, there's no quick fixes here. Check everything carefully. .

Good luck.

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