Just Completed Electrical Conversion to DC . . .

[Tripilot]

Fellow KDX’ers! I just wrapped up final testing on my '03 220’s electrical system conversion from an AC to DC, complete with charging and a 6 AH LiPo battery. I made a quick video that I’ll post here. I got most of the fundamental information from a variety of internet sources. I relied on a friend who is 1400 miles from me for advice when I got stumped, more than a few times. He’s an avionics technician and I am electrically challenged. This was a fun and rewarding project for me to complete. I will work on putting together a list of the parts I used for this conversion in case anyone is interested. Plated in South Dakota and insured, my KDX is reasonably street legal. I took it on the road yesterday and a guy I was following pulled over to watch me go by - Braaaap!, likely wondering about a smoker on the road with lights and all. Several others in neighborhoods gave me thumbs up when hearing the bike go by.

Battery-

Plate Lights-

Plate holder-

Universal Light Turn Signal Switch, Flasher Relay & Horn- This switch is superior to the Tusk, which I also bought but decided not to use.

Turn signals-
These are impressive and do not require the installation of a flasher for them to function properly. They also have the bright white LEDS when the turn signal is not being used. I didn’t use the white for the rear mounting as they are too bright. These are made to wrap around the upper fork, but fit nicely on my bark-busters. I made a mount for the rear using a pice of aluminum flat stock attached to my license plate holder.

Brake switch-
I installed a single switch on my front brake line. Using the rear will require some adapting because of restrictions.

Trail Tech Regulator/Rectifier-


Battery Tender accessory cable that can be used for a variety of tasks-

Switch-
This serves as a master to turn off/on all of my electrical at one time. If this switch is off, none of the lighting/horn will function, for the obvious reason.

85 Watts Stator from Ricky Stator- https://www.rickystator.com/product/sta ... coil-89-on
I plan to rewind the original stator that I removed for the new install to see if I am able to get more than Ricky’s 85 watts, simply out of curiosity and to attempt something else I’ve never done.

UFO Rear Fender- https://www.ebay.com/itm/333211305173
I ordered and installed one of these because I didn’t want to make holes or otherwise damage the original fender. As it turns out, I could have left the original on because I dint go the route I originally intended. Thats said, there is a possibility of building a small, aluminum fender rack that. I you choose to use the factory rear fender, you can buy a tail light for a WR450R that is a direct fit and haas a tail/brake light combination. I bought one via eBay that I will use if I go back to the original fender. This light will not fit the UFO fender.
NOTE- The light socket on the UFO fender is plastic garbage and I had to swap it out for a metal one-
It’s really poor that UFO makes a descent fender and installs plastic junk to save a few cents and create aggravation and work to make it correct.

I built up my wiring harness using individual wires. Doing it again I would purchase a trailer wiring harness with four wires- Brake, LT, RT & ground. I would run them to the front where the battery is located and connect to the front turn signals using 2 into 1 butt connectors for a much neater/cleaner installation. It’s not a difficult task to accomplish and it’s cool to have a KDX with a a fully functioning electrical system.

[KDXGarage]

Welcome! Come on in!

That's a very nice first post. Thanks for signing up and posting all that.

Instructions to add pics are in my signature.

[SS109]

Awesome! Now get us some pics and video! Also, if you can, it might be helpful to some if you post up your wiring diagram as this question comes up fairly regularly.

[bufftester]

Welcome to the forums and congrats on diving right in.

[GOT WOODS?]

I'd really like to see a wiring diagram as well. Did the conversion to my 03 220 and it has worked well so far. I noted that you talked about a charging system, but I see the battery tender in the pics. Were you able to wire it so it self-charges the battery, or do you charge the battery through an exterior battery charger? Would love to get mine to self-charge.

Unless you really want to mess around with the rewind, the LED's draw so little I wouldn't bother. My LED headlight is super bright and draws next to nothing with the stock stator.