2k-3 Swap and adding headlight

[Brian]

So I am going to swap the 2k-2 I have on my bike (2006 EC250) for a 2k-3 as well as add a headlight. So I thought I would document with pictures, wiring etc in a thread.

Parts List:
2k-3 stator
Regulator/Rectifier Trail Tech Part #7003-RR150
3 position switch w/Kill Switch Trail Tech Part #040-HBS-02
X2 Halogen Head Light Trail Tech Part #36T2-70
Flywheel Puller Motion Pro Part #08-0026
Battery Turn Tech 2.5 Ahr Battery

LED tail light; rear fender seems pretty floppy already. Is a tail light just going to make it a lot worse? How do you mount it? Suggestion on which one?

What am I forgetting in my parts list?

Thanks

 

[eff]

Since you are adding a battery i assume you are planning to convert from an AC to DC system?

 

[slocalspode]

If you are going trailTech. You might want to look into
getting a whole kit. Something like this.
http://www.trailtech.net/ktm_s-8311_kits.html
You get a stator already with the floating ground mod.
for DC output.
I did this mod on my '02 XC300 a couple of years ago.
As for the floppy rear fender. Do you have the sub-frame
loop support under the fender?
Keep us up to date on your progress.
Jeff

 

[Brian]

I bought a rewound 2k-3 from widebear in November. So I already have one...if I'm not mistaken I think its already setup for DC, floating ground. But I will have to verify.

 

[slocalspode]

I think you are right. I remember that one for sale and was thinking
of picking that one up from him also. If I remember correctly I got
my 2K3 from him a few years ago, but, it did not have the mod
done to it yet.
Are you going to set your's up with turn lights, brake lights,
hi-lo beam etc...?
If so. You have to replace the Leonelli AC flasher with a DC flasher.
I use oned from an auto parts store. I also had to swap the orange
and black wire on the flasher module connector.

You can swim throught here for a couple of more pictures of my EC300
http://s288.photobucket.com/albums/ll172/SloCalSpode/ec300/
It shows my battery set up and the 2K3 post floating ground mod.

It is the yellow wire with the shrink tubing in the above picture.
I think most of this was covered in the "HOw to go DC" thread.
Good luck with your upgrades.
Jeff, So Cal.

 

[Brian]

As for the floppy rear fender. Do you have the sub-frame
loop support under the fender?

Do you mean part #53?
http://www.gofasters.com/images/FRAME-06.jpg
Pretty sure I don't. I think that would help.

Are you going to set your's up with turn lights, brake lights,
hi-lo beam etc...?
If so. You have to replace the Leonelli AC flasher with a DC flasher.
I use oned from an auto parts store. I also had to swap the orange
and black wire on the flasher module connector.

I'm thinking hi-lo, brake light. Only thinking brake light for the rear visibility at night, might be a good idea.

Thanks for the tips. Hope to get into this very soon.

 

[slocalspode]

Yes, part # 53. It will make the rear fender much stronger.
You might try posting "WTB" add here and see if anyone has
a spare to sell.
Good luck and lets see some picts when you get done.
Jeff

 

[Brian]

Finally making some progress on this...
Have the stators swapped. Ran it for a few seconds and it seems good. However I read that you can change the timing based on the orientation so I better double check that. Still need to get some stuff to wire everything up and figure out what to do about mounting the battery.

2k-2

2k-3

Schematic

I'll put up a better schematic later. Still should find some sort of LED strip I can glue under the fender....

 

[widebear]

Looks good.That stator was rewound as well, prob could cook your thanksgiving turkey with what it puts out.

 

[slocalspode]

Excellent. Keep us updated with your progress.
I wish your 2K3 stator picture was in better focus.
It does not look the same as the one I did.
Your yellow wire looks like it is still soldered to
the terminal at the top. I can't tell if one of the
winding wires have been cut and attached to
the yellow wire. (see my picture for ref)
I wonder if the (floating ground mod) has
been done to this stator? Just curious.
Jeff.

 

[widebear]

Yes Baja Designes did it. Now my buddy does them for a box of beer, after seeing how he does it I do it myself while drinking beer.

 

[Brian]

Excellent. Keep us updated with your progress.
I wish your 2K3 stator picture was in better focus.
It does not look the same as the one I did.
Your yellow wire looks like it is still soldered to
the terminal at the top. I can't tell if one of the
winding wires have been cut and attached to
the yellow wire. (see my picture for ref)
I wonder if the (floating ground mod) has
been done to this stator? Just curious.
Jeff.

Ya I was moving quickly...I thought the pics looked ok on the camera screen. When I pop the flywheel off again to check out the timing, I'll take a better picture. I don't understand the floating ground mod...I'll search around for the difference. I get the premise but I don't see what difference in wires would be.

 

[Brian]

Looks good.That stator was rewound as well, prob could cook your thanksgiving turkey with what it puts out.

I am working on LED replacement for the lights in my X2. Its going to be stupid bright.

 

[moto9]

Yes, part # 53. It will make the rear fender much stronger.
You might try posting "WTB" add here and see if anyone has
a spare to sell.
Good luck and lets see some picts when you get done.
Jeff

Ya, I'd like to see pics of the scoot when she's all finished up.

I am almost ready to do my scoot, Still waiting on a head light and a bar switch.

I don't plan to ride it at night, just want it cop legal to hop between trail.
So, I'm hoping I can light up the headlight and tail light off the K2 stator without modifying it...I will if necessary.
As for the horn, blinkers, the'll stay off until I need the yearly safety check, then Ill just throw a 12v battery in the air box and mount up the extras.
So, for the tail light (and I'll have to get some pics) I have a Baja Kit off a CR 250 That I kept when I sold the bike, I pulled the LED light off the under tail kit, drilled 2 holes in it and bolted it under the lip of the rear fender.
we'll see how long it lasts...4 rides...it's still there.

 

[GMP]

I used an LED side marker light for a trailer from Autozone, fit perfect on the '07. No brake light though, but all I cared about was being enduro legal. Moto9 you will be fine with a basic 35W-40W enduro headlight, Hebo Granada on my bike now works with 2K-2.

 

[Brian]

I can't seem to find a configuration to mount that battery (Turntech 2.5 A-hr) in the air box that I am happy with. Anyone have any advice on that?

 

[wence]

I can't seem to find a configuration to mount that battery (Turntech 2.5 A-hr) in the air box that I am happy with. Anyone have any advice on that?

You may not be happy with this either but it is what I have done and has been working fine for over a year now.
I drilled 4 holes in the base of the seat and threaded cable ties through. I then strapped the battery to the underside of the seat with enough length on the leads so that when I am doing an air filter change I just hang the seat off one side of the bike with a spare looped cable tie. I loop this through the base of the rec/reg which is screwed to my rear guard behind the bracket under the seat.
I will try to get some shots and post it up.
Cheers Mark

 

[Brian]

I hadn't thought of that possibility yet, I'll take a look. Though it may be slightly different because I have the side door air filter access on my 06. But I would be interested in seeing pics. Thanks Mark.

 

[wence]

Five minutes and you should see them..... Beware: very dirty bike, needs to be washed today after my paddock ride.

 

[wence]

andP1030252.jpg[/IMG][/URL]and

Hope this helps mate.
Any questions on my setup feel free to ask.
Once again sorry it is such a dirty bike ....
Cheers Mark