E start gear & headlight

[Jer]

I?m working on collecting all the parts to convert my 2008 ec200 to be e start.
I?m able to buy everything from cpd or eBay other than the gear that goes on the flywheel. They have the gear for the newer ones (2014 and up) but I don?t think it will fit mine. Correct me if I?m wrong.

Wondering if someone would be willing to part with theirs or if someone knows where I could buy one online.

I don?t think I will be getting the new subframe with the battery box or getting all the oem wiring. I?ll just build the wiring harness myself and use some generic button I have. If I do this right will I have any problems?

I also had a question about the headlight on my bike. I tried wiring in a 4in round led work light in place of my old non led headlight. It worked for 10-15 minutes. Then it went dim then it just stopped working. No wires came in pluggged, I tested the light on a battery and it?s now only lighting up a little bit on half the leds. (Barely even able to tell it?s on). Would the AC power that the bike makes be too much for the light maybe?

 

[SS109]

Good luck finding a starter gear. They are rare. Just follow the wiring diagram for the 2013 XC model for proper wiring of the e-start setup and so your battery will charge correctly.

As for the LED headlight, most modern LED lights that can only handle DC voltage. You probably damaged the electronic circuitry that controls the LEDS. When you do the wiring for the e-start/battery you should end up with a DC only circuit. Then, you can run an LED headlight directly from the battery.

 

[(F5)]

Agreed. You will need a decent rectifier regulator and a battery to reduce (practically remove) the AC ripple on the lighting cct.

 

[Jer]

I?ll keep looking for a gear but I?m the meantime I?m going to get an AC DC converter from Amazon. I ordered this one for like 20 bucks. Hopefully it works. The light I?m using is a 10-30w it says.

Step Down Voltage Convertor, AC 10-28V to DC 12V Buck Voltage Regulator Waterproof Power Module for Car, Waterproof Step Down Module(3A) https://a.co/d/bkjZyKW

What if ordered the e start setup of the new rieju bikes? Looks like it should bolt right on. All of the parts should be available for the newer bikes. Would probably be more reliable too. It looks like I?d need a whole new flywheel and possibly stator. What do you think I?d all need?

 

[(F5)]

Sounds like you are over investing in an old bike.

Bearing in mind I just came back from a great weekend on my 07.

 

[Anders]

Step Down Voltage Convertor, AC 10-28V to DC 12V Buck Voltage Regulator Waterproof Power Module for Car, Waterproof Step Down Module(3A) https://a.co/d/bkjZyKW

My first thought is that 36W is perhaps not enough to charge your battery AND drive a headlight, even if it is LED.

 

[Jer]

Sounds like you are over investing in an old bike.

Bearing in mind I just came back from a great weekend on my 07.

Maybe, but I?ve rode newer ktms and I?m yet to find a bike that I like more than this 200

 

[Jer]

My first thought is that 36W is perhaps not enough to charge your battery AND drive a headlight, even if it is LED.

I won?t be connecting a battery. It just has to run the 10-30v led

 

[Neil E.]

I won?t be connecting a battery. It just has to run the 10-30v led

So what will operate the starter motor when you get all the parts? You should plan it out and prepare for the estart if that's your end goal. Keep in mind that the Amazon voltage converter shows a maximum input voltage of 28AC.

I assume your stock voltage regulator is properly clipping the stator AC output to say 14 volts. If so the Amazon converter should work. There have been people in the past that have had issues with the stock voltage regulator. When it fails the AC voltage goes high enough to burn out all the light bulbs. This would also take out the Amazon device.

Keep in mind that the coverter output should connect only to your new light. Do not ground either of the DC wires. Your new LED light will be an isolated circuit.

 

[Jer]

So what will operate the starter motor when you get all the parts? You should plan it out and prepare for the estart if that's your end goal. Keep in mind that the Amazon voltage converter shows a maximum input voltage of 28AC.

I assume your stock voltage regulator is properly clipping the stator AC output to say 14 volts. If so the Amazon converter should work. There have been people in the past that have had issues with the stock voltage regulator. When it fails the AC voltage goes high enough to burn out all the light bulbs. This would also take out the Amazon device.

Keep in mind that the coverter output should connect only to your new light. Do not ground either of the DC wires. Your new LED light will be an isolated circuit.

I can?t find a starter gear that will fit my bike so the only way I can get e start is by waiting for a used one to show up. I already have the led light and I just wanted to get it working in the meantime since it will probably be months before I find a gear. Then I can just re wire if I?m able to get all the parts I need for e start

I will test the voltage going into the converter before I hook it up. Although it ran my old headlight before with no issues.

 

[(F5)]

No issues apart from it burning out? LED and electronics require a stable DC voltage without too much ripple. Incandescent bulbs care not, it's all just current warming up a heating element so either direction is fine.

You could consider a Ranger or MR300 perhaps? That would give you electric start and new brakes, suspension etc etc. I loved my 200 but rode a mates 300 and realised it felt no heavier.

Just a thought. I cheated and went Blue (see signature) but still love my 300 for more open stuff with KYB fork mod. But I've fed it low mileage carb, calipers, master, etc to keep it fresher than an old bike is often.

 

[Neil E.]

No issues apart from it burning out? LED and electronics require a stable DC voltage without too much ripple.

The Amazon device should have internals that could survive considering it's meant to accept an AC voltage input. Likely a full wave rectifier with *some* form of ripple smoothing. I guess it's a question of how good the LED lamp is; a few of the expensive ones have a wide voltage range (and maybe better tolerance). Release the magic smoke!

A question for F5. I see the Suzuki Stinger in your signature. I think it's one of the neatest little zingers ever made. Is insurance affordable enough to keep your whole fleet "roadable"?

 

[Jer]

No issues apart from it burning out? LED and electronics require a stable DC voltage without too much ripple. Incandescent bulbs care not, it's all just current warming up a heating element so either direction is fine.

You could consider a Ranger or MR300 perhaps? That would give you electric start and new brakes, suspension etc etc. I loved my 200 but rode a mates 300 and realised it felt no heavier.

Just a thought. I cheated and went Blue (see signature) but still love my 300 for more open stuff with KYB fork mod. But I've fed it low mileage carb, calipers, master, etc to keep it fresher than an old bike is often.

One day I?ll get a new bike but I enjoy tinkering and fiddling with my 200. I?m still faster than all my friends so I have no reason to upgrade plus I have a bike that no one else on the trail has or even recognizes I think I?m just as happy putting the money of a new bike into this bike. Maybe that?s weird but it?s what I like to do

 

[SS109]

One day I?ll get a new bike but I enjoy tinkering and fiddling with my 200. I?m still faster than all my friends so I have no reason to upgrade plus I have a bike that no one else on the trail has or even recognizes I think I?m just as happy putting the money of a new bike into this bike. Maybe that?s weird but it?s what I like to do

Eh, you're not alone. I would rather sink my money in to an older bike and make it exactly how I like it. I spent way too much on my '90 KDX200 I built. It got all the goodies, took a while as I went through every single part on that bike, but it was all worth it to me! Same with my '11 EC250R. Lots of people said I should just part it out but I love the bike. It just fits me. So, spend away, my friend. If you like it that's all that matters!

Pics of my recently redone Gasser and my KDX...

Before...

Now...

My old KDX... before...

After...

 

[(F5)]

Yeah the Stinger is a long term project. I made some real progress when recovering from a collarbone injury, but what with several other bikes just got put to side again.

History repeats itself and I'm lying here with suspected break on other side so I will likely get it going shortly.
We have classic rego here so not too bad if I want to get it legal.

 

[Jer]

Eh, you're not alone. I would rather sink my money in to an older bike and make it exactly how I like it. I spent way too much on my '90 KDX200 I built. It got all the goodies, took a while as I went through every single part on that bike, but it was all worth it to me! Same with my '11 EC250R. Lots of people said I should just part it out but I love the bike. It just fits me. So, spend away, my friend. If you like it that's all that matters!

Pics of my recently redone Gasser and my KDX...

Before...

Now...

My old KDX... before...

After...

Those are both beautiful! Great job on them. Makes me want to fix mine up even more.

 

[Anders]

One day I?ll get a new bike but I enjoy tinkering and fiddling with my 200. I?m still faster than all my friends so I have no reason to upgrade plus I have a bike that no one else on the trail has or even recognizes I think I?m just as happy putting the money of a new bike into this bike. Maybe that?s weird but it?s what I like to do

I am considering a new Rieju MR 200, but I havnet't really made up my mind. I could of couse do yet another big service of my '15 EC200 to keep it going for another year. It has done 400 hours now, but still works well.

There may be a rwason to upgrade, as the '18+ (Rieju now) chassis has got rave reviews all over.

Time will show.

Sent fra min YAL-L21 via Tapatalk

 

[Jer]

My ac/dc converter from Amazon came in and I installed it on the bike along with a new LED light. The light works great. Very bright and only minimal flickering at idle (about the same as my old light). Only odd thing is that the light shuts off if the bike revs really high. I?m guessing at like 9,000rpm. If you flick the switch off and on again it will work perfectly again. I?m not to worried about it since I don?t usually rev that high, especially in the dark. My only worry is that this means my light is being over volted and will eventually burn out either the ac-dc converter or the light itself again.

 

[(F5)]

What does your meter say?

 

[Jer]

What does your meter say?

I?ll have to borrow a voltage meter and check