Wiring the Baja Designs Kit

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Wiring the Baja Designs Kit

Post  kunz82414 on Mon Jan 21, 2013 4:54 pm

Hello, new here. I have owned my XR for a couple years and recently started wiring in a Baja Designs dual sport kit. Seems relatively easy, but I am not sure about splicing into the stator wires. The bike was purchased used and I am told it has a rewound 200W stator. According to the Baja designs instructions, I should have 2 wires or 3 wires, but I have a lot more. I also don't know if I splice into the existing wiring with new wiring and leave or disconnect the present connections and connect directly to the new wiring. Any help is appreciated. Photo of wiring attached:

https://www.dropbox.com/s/085lag6zx23s106/Photo%20Jan%2006%2C%203%2027%2022%20PM.jpg

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Re: Wiring the Baja Designs Kit

Post  Mauser on Mon Jan 21, 2013 7:04 pm

Welcome to the forums, I would pull the stator cover and check which sets of windings go which set of wires, also which go to the pickup etc....write these down on a pad and start from there, you should have 2 x 100w at a guess ?....6 wires in total ?

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Re: Wiring the Baja Designs Kit

Post  kunz82414 on Sun Feb 24, 2013 4:33 am

So it turns out that I have 4 wires coming out of my stator shown here:

https://dl.dropbox.com/u/69360029/Photo%20Feb%2017%2C%201%2045%2055%20PM.jpg

I don't know what to wire to my Baja designs kit as the instructions do not describe a scenario that has 4 wires. I tried unplugging the 2 stock female connectors and plugging them into the Baja designs male connectors hoping that would work, but no such luck. Any help would be appreciated; I am obviously not great with the electrical end of things. It seems strange that the stock harness just gets unplugged. It would make more sense to me to splice into it.
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Re: Wiring the Baja Designs Kit

Post  Mauser on Sun Feb 24, 2013 9:24 am



Hope you can see this OK but there are 4 wires from the coils, 3 carrying AC back to your regulator/rectifier under your seat, it don't matter which wire goes where as they are all carrying AC. The 4th wire is a ground...but then as shown on the picture you should have another pair for the pickup..labelled ignition pulse generator ?. I am sure you have 2 more wires hiding behind the 4 you can see ?, post a picture of the other end of the wires please ?.


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Re: Wiring the Baja Designs Kit

Post  kunz82414 on Sun Feb 24, 2013 5:11 pm

Thank you, I will try to get a better picture but this is the other end:

https://dl.dropbox.com/u/69360029/Photo%20Jan%2006%2C%203%2027%2022%20PM.jpg


It looks like the previous owner wired in some lighter gage wire for something. I might peel off all the sheathing and get a better picture of what is going on. Thanks for the help.
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Re: Wiring the Baja Designs Kit

Post  kunz82414 on Sun Feb 24, 2013 5:59 pm

I did a little research and found this photo:

https://dl.dropbox.com/u/69360029/IMG_0263.jpg

This is basically what I have coming from the stator. I have not investigated how all the other wires splice into this within the sheathing, but based on my research, the square connector connects to the ignition pickup. Is this the set of wires that need to be attached to my new Baja designs wiring harness? Am I trying to find the "ignition pickup" wiring? Thanks
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Re: Wiring the Baja Designs Kit

Post  Mauser on Sun Feb 24, 2013 6:34 pm

So there are 6 wires as I pointed out earlier lol.
I would connect the plug connector to the ignition module sometimes called CDI unit. Then get a test meter and see which of the remaining 4 wires is your earth.....or as you suggest strip off the cover and see what's going on underneath....looks like you will find soldered wires as the colours coming out of the stator don't match further along the wires listen up
Shouldn't be difficult to sort out ?.....your wiring is a right mess I couldn't sleep knowing my baby was that untidy Frustrated

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Re: Wiring the Baja Designs Kit

Post  kunz82414 on Sat Mar 30, 2013 4:21 am

Just in case anyone has the same issue...It turns out that I have a dual output stator (2x125W). I hooked up one output to the Baja Designs kit and the other to the stock rectifier. I also had to purchase another Baja designs relay and wire it into the kit to make everything work. Right now everything seems to be working like it is supposed to.
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Re: Wiring the Baja Designs Kit

Post  Mad Frosty on Sat Mar 30, 2013 1:57 pm

I have the BD kit ready and the Ricki 2x100W stator + the upgraded voltage regulator that can handle more juice than the stock one , still not sure about which way to go , single loop ( stock ) or two loops one for the bike and one for the BD kit . I was searching for more info about this ( as the BD and Ricki manuals are useless ) but have had no luck , there is not enough detailed information about this nor photos . Surprising considering how many people have done this .
I think i prefer to go the dual loop route , my bike is the euro model , it already has some of the components which came with the BD DS kit like the regulator rectifier etc , also i dont want the battery as it just adds weight to the bike has anyone removed it ?
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Re: Wiring the Baja Designs Kit

Post  kunz82414 on Sat Mar 30, 2013 4:08 pm

I was lucky enough to have a BD stator and found this little supplement to the original install manual:

https://dl.dropbox.com/u/69360029/installation-instructions-for-rewound-stator-on-xr650r-with-quick-release-dual-sport-kit.pdf

I wired it exactly as this document states and purchased the additional relay from BD to make it all work. I did not have any accessories work until I installed the relay; now everything works fine.

I wish I understood electricity as well as I understood other mechanical subjects, but I don't know exactly what the electrons do when they are routed to different components of the bike and am still trying to understand exactly what I did. I'm just glad it all works.
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Re: Wiring the Baja Designs Kit

Post  Mad Frosty on Sat Mar 30, 2013 10:55 pm

Looking at the schematics and failing to see the full circuit , where is the main light ? What amperage rating is the relay ? , the people from baja designs never told that i need one ( the kit is complete ? clearly not ) Rolling Eyes

I am starting to feel frustrated now as nothing works straight out of the box , everything need to be modified or i need to order extra parts and the build is going nowhere .
BTW the BD DS kit its good but not 600$ ( incl led indicators , delivery ) good , some of the plastics have been cut by 7 year old blind kid .
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Re: Wiring the Baja Designs Kit

Post  Mauser on Sun Mar 31, 2013 9:38 am

Would guess headlight is on the white yellow from the AC regulator side top of drawing Bump
You must post some pictures of this kit so we can understand how bad they have cut/made stuff ?.
Going back to your relay I would suggest it would be a 10amp..... 125 watts @ 12 volts is about 10 amps in English units lol.....no doubt the off shore guys will have some funny conversion 125 palm trees @ 12 rocks is about 10 lamp posts...but you get the idea razz

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Re: Wiring the Baja Designs Kit

Post  Mad Frosty on Sun Mar 31, 2013 1:00 pm

Stanley knife and file used to smoothen the ruff edges , it looks better now not perfect . Most parts in the kit are good quality , its just the plastics which are nowhere near OEM quality level , also the new horn is attached on a piece of butter plate no wonder people have had them come off .
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Re: Wiring the Baja Designs Kit

Post  BuRP on Tue Apr 02, 2013 11:02 am

Kunz,

you leave the ignition/pickup wire/connector well alone!!!
Mess with anything else but leave that bit alone, you've been warned....... (ominous face) BRP smile
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