Sort of GS related....

I am working on getting my XR street legal so I need to add some extra lights and stuff. I can buy a Baja Designs kit but I do not want to spend the $400+ for it. Plus I have most of the parts from vaious donor bikes that I have acquired over the years.

The main concern is the regulator/rectifier. The stock stator can supply enough power for a 35watt headlight bulb, but anything greater requires it to be rewound.

Can any reg/rec work, mainly from a GS (since I have a few)?  :dunno:

All it needs to do is run the headlight, turn signals, brake light and horn. There is not a charging system since it is a kick-start, I wish it had an e-start. The Baja Designs kit does have a small battery to run the lights when the bike is off, which I think is required by law in some states. So some charging of the battery is needed.

Hmmm. Good question. I would think that the GS, being built for a heavier load, would work IF the input of the XR stator is a three phase source. The regulator portion only kicks in if the input level reaches a trigger point.

Counter question: How many wires are coming out of the XR stator and where does the stator output go? I would need to see/understand that circuit (or some facsimile of it) to make sure that is a three phase output.

I have seen some of the dirt bike stators ... they only have the alternate coils ... the core is shared with another street bike possibly ... just swap that bike's coil and you're good ... Look at electrex's site for dimensions etc that are similar to yours and find one off that model in the junkyard ... and regulators ... OK no idea ... I am still wrapping my mind around the fact that my virago has 3 wires comming from the reg and they all plug in the alternator ... that's it ... like WTF ... where is output out of the R/R comming from ...
Cool.
Srinath.

There are 4 wires from the stator. 2 go to to the AC Regulator and 2 go to the Ignition Control Module.

So basically the regulator is just a limit switch which prevents too much current from entering the electrical system. Using a regulator with the wrong trigger point could do damage.

I can just get a regulator from Baja Designs for only $49. Looks like I can just buy the individual replacement parts of the items that I need instead of buying the whole packaged kit.

As for the stator, rewinding the stock one is $120 for use with a 55w headlight or a new high power stator with 2x100 watts of power is $195.

For the stator ... find the cross over street item ... electrex has dimensions on their site ... get one that has same ID/OD and thickness (sorta like a wheel bearing) ... then swap it out and use a R/R and use up all the extra power with lights, T/S, Horn etc ... better to use more than use less ...  :lol:  ... heck run an A/C unit ... god knows this heat you need one ...  :lol:
Cool.
Srinath.

Nothing else useful matches to its size.

Electrex sells a "Dakar" dual-sport kit for XR400R called 94-2230K, which includes all the lights and a rectifier ; they also mention a competitor called Baja.  Their kit appears to work with the existing stator, although they mention "XR400/650 recommended use of G44 high-output stator" by the XR650.

See also http://www.sparxelectrical.com/Single_Phase_Regulator_Rectifier.htm and http://www.procycle.us/main/dskit.htm for stuff you can use if you've got 12v AC power already (check voltage to the light with a voltmeter).

It is not so easy to make the dirt bikes lighting street legal. Remember that the stator has seperate windings to charge the capacitor in the cdi unit so even if a three phase ac generator off another bike could be fitted, you would need a new ignition system. I've seen xr's with license plates but I don't know how to go about getting them.

Try ricky stator.
http://www.rickystator.com/pages/XR600stator.html

If you already have all the parts (lights, blinkers, switches) and if you are comfortable designing and building a simple wire harness, then this is a doable project that will be better, and a lot cheaper, than a kit.

An xr400 is a great bike to make into a wicked little street bike. Lace up an 18" front rim with big road tires, 10 or more teeth smaller on the rear sprocket. You'll be amazed how fast and nimble it is.

Here is my 74 xl250. 18x2.15 alloy front rim vs. 21x1.60 stock.  

It is not that hard to make a dirt bike street legal. I do know of the kits that can be bought for the conversion. Like I said, I was just trying to see if I could do it cheaper than with a $400-500 kit. The price is hard to justify with what little you get. Especially since I have most everything already, just need to be creative with it.

As for wheel & tires, I am going to use GS wheels. They were common with street 'tards. I have not checked the XR's bearings and axle sizes yet, but I will probably need to replace the GS bearings. The rear rotor will need to be modified. Also, caliper brackets and spacers will need to be made. All easy stuff.

will(did they make) a XL400?
charging system work?

another choice.....
since it has enough to power a little H/L bulb and tail light....
get a battery hooked in  
to take up the surges or to just power the brake light and horn