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/l...alSpode/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]

Originally Posted by slocalspode

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.

Originally Posted by slocalspode

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.