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.
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2011 EC250E
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