Title: KLR Alternator Mod
Sourced From: advwisdom.com/a/klr-alternator-mod/
Published Date: Tue, 14 Jul 2020 02:58:24 +0000
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 way 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:
and the oil screen cleaning Step-by-step here: http://klrworld.com/forums/index.php?topic=915.0
My bike is a 2007 KLR650 with 1,600 miles
Start with a little research…You�ll have to excuse the crudity of my KLR-650 library. I really need to organize the topics better…hehehe
First Drain the oil, I use the center stand for this task
Low profile magnetic drain plug, new crush washer with every oil change.
Now jack-up the bike, Jack is a Sears Craftman brand with a few added brackets
remove side covers, notice re-located helmet lock with cable. Easy access and attach full face helmet.
remove seat. All my KLR fasteners have been upgraded to stainless �cap� style fasteners (Allen Key) See: http://klrworld.com/forums/index.php?topic=878.0
Remove tank bolts
Gas off, remove gas line
rag to catch gas drippings
side covers pry from tank
All the Items removed
set up bike for task….Lots of light
Shop space/tables open…tools available
the doo kit from Eagle Mike…Will need that outer gasket for the stator
Area to open up!
Shifter lever off. Small mart to re-align teeth when re-installing
Take bolt all the way out…rachet wrench works best…wiggle lever off…
set aside with bolt in place as to not lose
one peg bolt off…loosen other…swivel aside as to clear outer case
sprocket cover next….3x fasteners
neutral wire….grab with fingers…wiggle straight back..no problem
wire off ….connector exposed
remove kick stand switch cover for better access to wire bundles to thread
loosen outer cover…..NOT inner cover…triple check which bolt is attached to outer cover
loosen all about this much…your fasteners may not be cap heads
notice inner cover fastener still fully engaged
loosen wire bundle bracket
remove bracket…long bolt comes with it
crack the case…try to maintain integrity of gasket…If tears….you will need a new one. Mine tore.
remove all fasteners here shown is 2x helper tabs to assist in prying with fingers
keep all parts on table with labels
pull outer case straight back…some oil will drip…have rags handy
tie off stator…don�t let wires hold it�s weight! Have wires/string/bungee available prior to removal
here is is
lay on small table to work
with lots of light
need to remove this bracket screw
and these 3x attach cap bolts
stupid screw phillips head thrashed
get out drill…place rags around work area….tip cover to side
drill slow..don�t let chips fly
use depth gage to predict when manufactured head will be drilled off
there we go! Head off….no damage to bracket
un-thread screw threads with fingers…easy
area where removed
the parts removed…need to find replacement
Metric coarse thread M6-1.0 see: http://klrworld.com/forums/index.php?topic=721.0 for KLR650 specific fastener data
find torque while at it…use this KLR fastener chart
go to your fastener bin and find a match…use stainless cap head style
The correct matching length 12 mm
remove rubber wire seals…pull/pry off case
new 400 watt stator to install
follow wire path to radiator overflow location on bike. Thread new wires following OEM wires
route thru here
zip tie as you go
disconnect OEM re-connect new
Take old out….Don�t sell on E-bay yet!
need some of this stuff
apply to the wire gaskets…Note the new stator has only 1x wire gasket while the OEM had 2x wire gaskets
place bracket back in place
torque to 61 in-lbs
tighten this new bolt
Check 3x stator torque values….Use 61 in-lbs for a 6mm bolt…
3x bolts torque
prep outer gasket…light coat both sides
ready to reinstall case
finger 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.
toruque to 25 inch-lbs cris cross pattern…repeat with 68 in-lbs.
All buttoned up
re-attach wire bundle clip and push wires back into slot with small tool
Re-attach wire bracket with long bolt 68 in-lbs
cut zip ties
Now 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�s socket
regulator extra wire location
just eeked it in….contacts the rubber bumpers
loktite the attach fasteners…the blue paste type
add oil, re-attach shifter, foot peg, neutral wire
Review and observations:
1. Bike started….
2. No leaks….
3. The headlights dim a lot at idle….light up when throttle is engaged. I don�t believe this was the case with OEM stator.
4. Have left side outer cover gasket handy. I needed one.
5. Have a M6-1.0 10 mm stainless cap screw available.
6. I would not say this is a �plug and play� install
7. 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
Still 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!