{"id":534,"date":"2020-07-14T02:58:24","date_gmt":"2020-07-14T02:58:24","guid":{"rendered":"https:\/\/advwisdom.com\/a\/?p=534"},"modified":"2020-07-14T03:00:46","modified_gmt":"2020-07-14T03:00:46","slug":"klr-alternator-mod","status":"publish","type":"post","link":"https:\/\/advwisdom.com\/a\/klr-alternator-mod\/","title":{"rendered":"KLR Alternator Mod"},"content":{"rendered":"

Enclosed are step by step detailed instructions for installation, lessons Learned, and review of the new whiz-bang 400 watt Electrosport stator and regulator . Since I’m \u00a0way there, I’ll be swapping out my Doo Hicky and cleaning my oil screen also. See the ~90 pictural walk-thru toutorial of the Doo Hicky swap here:
\nhttp:\/\/klrworld.com\/forums\/index.php?topic=950.0<\/a>
\nand the oil screen cleaning Step-by-step here: http:\/\/klrworld.com\/forums\/index.php?topic=915.0<\/a>
\nMy bike is a 2007 KLR650 with 1,600 miles
\n\"\"
\nStart with a little research…You\ufffdll have to excuse the crudity of my KLR-650 library. I really need to organize the topics better…hehehe
\n\"\"
\nFirst Drain the oil, I use the center stand for this task
\n\"\"
\nLow profile magnetic drain plug, new crush washer with every oil change.
\n\"\"
\nNow jack-up the bike, Jack is a Sears Craftman brand with a few added brackets
\n\"\"
\nremove side covers, notice re-located helmet lock with cable. Easy access and attach full face helmet.
\n\"\"
\nremove seat. All my KLR fasteners have been upgraded to stainless \ufffdcap\ufffd style fasteners (Allen Key) See: http:\/\/klrworld.com\/forums\/index.php?topic=878.0<\/a>
\n\"\"
\nRemove tank bolts
\n\"\"
\nGas off, remove gas line
\n\"\"
\nrag to catch gas drippings
\n\"\"
\nside covers pry from tank
\n\"\"
\nAll the Items removed
\n\"\"
\nset up bike for task….Lots of light
\n\"\"
\nShop space\/tables open…tools available
\n\"\"
\nthe doo kit from Eagle Mike…Will need that outer gasket for the stator
\n\"\"
\nArea to open up!
\n\"\"
\nShifter lever off. Small mart to re-align teeth when re-installing
\n\"\"
\nTake bolt all the way out…rachet wrench works best…wiggle lever off…
\n\"\"
\nset aside with bolt in place as to not lose
\n\"\"
\none peg bolt off…loosen other…swivel aside as to clear outer case
\n\"\"
\nLike this
\n\"\"
\nsprocket cover next….3x fasteners
\n\"\"
\nset aside
\n\"\"
\nneutral wire….grab with fingers…wiggle straight back..no problem
\n\"\"
\nwire off ….connector exposed
\n\"\"
\nremove kick stand switch cover for better access to wire bundles to thread
\n\"\"
\nloosen outer cover…..NOT inner cover…triple check which bolt is attached to outer cover
\n\"\"
\nloosen all about this much…your fasteners may not be cap heads
\n\"\"
\nnotice inner cover fastener still fully engaged
\n\"\"
\nloosen wire bundle bracket
\n\"\"
\nremove bracket…long bolt comes with it
\n\"\"
\ncrack the case…try to maintain integrity of gasket…If tears….you will need a new one. Mine tore.
\n\"\"
\nremove all fasteners here shown is 2x helper tabs to assist in prying with fingers
\n\"\"
\nkeep all parts on table with labels
\n\"\"
\npull outer case straight back…some oil will drip…have rags handy
\n\"\"
\ntie off stator…don\ufffdt let wires hold it\ufffds weight! Have wires\/string\/bungee available prior to removal
\n\"\"
\nAttach here
\n\"\"
\nhere is is
\n\"\"
\nlay on small table to work
\n\"\"
\nwith lots of light
\n\"\"
\nneed to remove this bracket screw
\n\"\"
\nand these 3x attach cap bolts
\n\"\"
\nstupid screw phillips head thrashed
\n\"\"
\nget out drill…place rags around work area….tip cover to side
\n\"\"
\ndrill slow..don\ufffdt let chips fly
\n\"\"
\nuse depth gage to predict when manufactured head will be drilled off
\n\"\"
\nthere we go! Head off….no damage to bracket
\n\"\"
\nun-thread screw threads with fingers…easy
\n\"\"
\narea where removed
\n\"\"
\nthe parts removed…need to find replacement
\n\"\"
\nMetric coarse thread M6-1.0 see: http:\/\/klrworld.com\/forums\/index.php?topic=721.0<\/a> for KLR650 specific fastener data
\n\"\"
\nfind torque while at it…use this KLR fastener chart
\n\"\"
\ngo to your fastener bin and find a match…use stainless cap head style
\n\"\"
\nThe correct matching length 12 mm
\n\"\"
\nremove rubber wire seals…pull\/pry off case
\n\"\"
\nlike this
\n\"\"
\nnew 400 watt stator to install
\n\"\"
\nfollow wire path to radiator overflow location on bike. Thread new wires following OEM wires
\n\"\"
\nlike this
\n\"\"
\nroute thru here
\n\"\"
\nzip tie as you go
\n\"\"
\ndisconnect OEM re-connect new
\n\"\"
\nTake old out….Don\ufffdt sell on E-bay yet!
\n\"\"
\nneed some of this stuff
\n\"\"
\napply to the wire gaskets…Note the new stator has only 1x wire gasket while the OEM had 2x wire gaskets
\n\"\"
\nplace bracket back in place
\n\"\"
\ntorque to 61 in-lbs
\n\"\"
\ntighten this new bolt
\n\"\"
\nCheck 3x stator torque values….Use 61 in-lbs for a 6mm bolt…
\n\"\"
\n3x bolts torque
\n\"\"
\nprep outer gasket…light coat both sides
\n\"\"
\nready to reinstall case
\n\"\"
\nfinger thread bolts…note: a .25 inch gap exists between case and frame. Cannot close with hand pressure….carefully tighten fasteners…cris-cross pattern 1x turn at a time. It will slowly close up the gap.
\n\"\"
\ntoruque to 25 inch-lbs cris cross pattern…repeat with 68 in-lbs.
\n\"\"
\nAll buttoned up
\nre-attach wire bundle clip and push wires back into slot with small tool
\n\"\"
\nRe-attach wire bracket with long bolt 68 in-lbs
\n\"\"
\ncut zip ties
\nNow for the regulator. Reach under rear fender to hold nuts. Un-thread bolts 2x. Un-clip wire socket and install new regulator…they included a long unnecessary wire to it\ufffds socket
\n\"\"
\nregulator extra wire location
\n\"\"
\njust eeked it in….contacts the rubber bumpers
\n\"\"
\nloktite the attach fasteners…the blue paste type
\n\"\"
\nadd oil, re-attach shifter, foot peg, neutral wire
\n\"\"
\nall done
\nReview and observations:
\n1. Bike started….
\n2. No leaks….
\n3. The headlights dim a lot at idle….light up when throttle is engaged. I don\ufffdt believe this was the case with OEM stator.
\n4. Have left side outer cover gasket handy. I needed one.
\n5. Have a M6-1.0 10 mm stainless cap screw available.
\n6. I would not say this is a \ufffdplug and play\ufffd install
\n7. Best to include a headlight “cutoff” switch. See step-by-step KLR650 headlight switch easy install here: http:\/\/klrworld.com\/forums\/index.php?topic=204.0<\/a>
\nStill some concerns about the mod….Seems like a lot of work and cost for the risk associated with this new Item. I hope Electrosport stands behind there products!<\/p>\n","protected":false},"excerpt":{"rendered":"

Enclosed are step by step detailed instructions for installation, lessons Learned, and review of the new whiz-bang 400 watt Electrosport stator and regulator . Since I’m \u00a0way there, I’ll be swapping out my Doo Hicky and cleaning my oil screen also. See the ~90 pictural walk-thru toutorial of the Doo Hicky swap here: http:\/\/klrworld.com\/forums\/index.php?topic=950.0 and […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[],"tags":[],"_links":{"self":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/534"}],"collection":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/comments?post=534"}],"version-history":[{"count":4,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/534\/revisions"}],"predecessor-version":[{"id":619,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/posts\/534\/revisions\/619"}],"wp:attachment":[{"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/media?parent=534"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/categories?post=534"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/advwisdom.com\/a\/wp-json\/wp\/v2\/tags?post=534"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}