EC300 2008 electrical overhaul - DC high output

[Wijnand]

Good day y'all.

I've been reading on this forum a lot, i'ts really helpfull!
For a year i've been riding my EC300 and I absolutely love it.

I'd like to run a cooling fan (with temperature switch sensor), heated grips and a more powerfull headlight. Because my wiring harness is completely shot (worn bits of wire isolation everywhere) I want to make a new wiring harness and convert te bike to DC with more electrical power at the same time.

This is the stator I'd like to use:
http://www.regulatorrectifier.com/c...d-hp-300-high-output-stator-and-regulator-kit

I still have to check whether it will fit but i'm waiting for my flywheel puller at the moment.

I want to make the wiring harness as simple as possible. No horn, no indicator lights, no indicator relay, no mapping switch.

What I do want:
strong headlight
normal rear light and brake light (front and rear brake)
Sensor controlled cooling fan
Switch controled heated grips
Rugged switches on handlebar, one to shut the engine off and one for normal beam/high beam.
Battery for stable electric output.

I will keep you informed with pictures.
Great ideas are always welcome!

 

[Moto7man]

Looks like a good project!

 

[Neil E.]

I emailed with the owner of ElectrexWorld (in the UK) a few years back when I was considering their three phase stator. He told me that ElectroSport copied their stators and had them manufactured in China. That would explain the quality issues if true. It will be interesting to see if your parts show a country of manufacture. The one you are considering is probably from ElectroSport.

Depending on how fussy you are, it is not necessary to go to a full DC system. I run my heated grips on AC, connected to the stator yellow wire. The rest of the bike is DC for lighting with the stock estart halfwave rectifier connected the the stator white wire. If you used a computer fan for rad cooling, the draw would be low.

By carefully selecting your lighting load (low draw LEDs) you could manage with a split system. Apparently Ricky Stator has a 100W stator that is an improvement on the stock ~70W stator (both are single phase). You would need to contact them since it is likely a KTM part number.

I'm interested in hearing how your conversion works out.

 

[Wijnand]

Hello,

I will check the UK. unit out for sure. I'm in the Netherlands so overseas shipping is always expensive.

Since I want to built my own wire harness, i'd like to keep everything DC. I think it will be easier (but i'm not sure yet).

My flywheel puller has arrived so I will be taking measurements

Edit:
My fan is a SPAL 80mm autosport fan, they suck realy hard (in a good way)