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450 Electrosport stator

  • Thread starter Thread starter davidduarte
  • Start date Start date
If you do the cleanup right, you shouldn't need the coil relay mod. I've gotten my voltage drop down from around 2v to 0.2 - 0.5v by cleaning everything up, including the guts of the ignition and kill switches which appeared to cause the most grief.

After doing that work, the coil voltage is generally just over 12v which I'm happy with.

I've yet to test my charging system fully, so that's all just with a car battery attached for the moment.

I may not need the mod, but I want to add a 12 volt plug and possibly wire up a horn relay too, so I figured I'd do it all at once. Anyway, here's the new wiring:

2011-07-29_15-20-39_850.jpg


2011-07-29_15-20-06_904.jpg


and some of the crummy old wiring:

2011-07-29_15-21-21_180.jpg
 
Love your work David, looks like you got the common ground done too!

Your crummy old wiring looks very similar to what mine was which is now gone also as part of my electrics relocation.

A 12v accessory plug and horn relay are definitely good ideas, so I can see why you were thinking the coil relay mod...

I haven't looked at the detail of the mod, but I think there's a way you can do it for the bigger bikes without cutting up the loom, whereas I think on our 450's we'd have to cut the loom for it to work...
 
as you can see from one of the pictures, the chain guard is missing. I replaced it a few years ago, but this one broke in the same place the old one did, at the rear mount point. I've been looking on eBay for a metal replacement, although I'm not sure if it will fit my bike.
 
speaking of dodgy wiring, I thought I'd look around some more, and found this:

2011-07-31_21-29-30_907.jpg


I squared that away with new connectors. My gas mileage had been lower than normal lately, so I figured I'd clean out the air filter. Here's what I found when I opened the air box:

2011-07-31_21-38-18_885.jpg


Damn chipmunks! Guess I have to go get some poisoned bait and take care of those little bastards.
 
Nice work David! You'll have a new harness before you know it... :rolleyes:

Those chipmunks sure look cute! I'm guessing they're a bit of a pest though? That would certainly kill your economy!
 
Nice work David! You'll have a new harness before you know it... :rolleyes:

Those chipmunks sure look cute! I'm guessing they're a bit of a pest though? That would certainly kill your economy!

They must have gotten in there within the past month or so. I started riding this season in March, and up until recently I was getting 55-58 miles per gallon regularly, dropping down to about 50-52 if I did any extended time at 65-70. Two tanks ago I got 47, when I filled it up yesterday it was 40, so I knew something was rotten in Denmark. I vacuumed out the acorns and shells, then removed the filter, cleaned it, oiled it, and put it back in. I checked the voltage again. I'm getting close to 14.5 volts at 4000 rpm, but it seems at idle I'm getting 12.5 to 12.8. I'll have to check it again tonight after work because it doesn't like to idle when it's cold, and even when it's warm it doesn't always want to idle. There are still other things that need to be done that I'm sure would help, but all in good time.
 
I'm pretty sure 12.5 to 12.8 at idle is aok as you don't really get any charging benefit until your up and moving. Idle should be enough to keep it running without draining the battery as such but that's about it.

14.5v at 4K sounds good too, so I'd say you've taken care of your charging issues :)
 
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