With most purpose-built dirt bikes ill-equipped to handle the dark of night, most trail riders pack up and head home before the sun sets. However, the determined Yamaha rider can outfit her YZ250 with lights capable of illuminating a dark trail by replacing her motorcycle's factory-equipped stator. Since the stock stator is designed to produce just enough power to charge the ignition system, replacing it with an aftermarket, high-output starter is the only way to go. Installation is fairly straightforward, but have the work done by a Yamaha technician if you doubt your ability to complete the task.
Things You'll Need
- Enduro headlight
- flywheel puller tool
- High-output stator
- Voltage regulator
Mount the headlight onto the motorcycle. Most aftermarket headlights are secured by rubber straps that wrap around the front forks. Wrap the straps tightly around the forks and loop the loose end over the strap's mounting hooks. Attach the black ground wire from the headlight to a bolt on the motorcycle's frame. Route the remaining power wire to the stator, securing it to the frame with zip-ties.
Replace the stock stator. Remove the left stator cover from the motor, using a screwdriver to unscrew the mounting screws. Pull the stator cover away from the motor. Remove the flywheel from the motor's crankshaft using a flywheel puller tool. Unbolt the stock stator, using a screwdriver to unscrew the mounting screws. Remove the stator from the motor and disconnect it from the motorcycle's wiring harness.
Install the high-output stator. Connect the stator to the motorcycle's wiring harness and slide it over the crankshaft. Secure the stator to the motor by tightening the mounting screws with a screwdriver. Reinstall the flywheel and stator cover, tightening all mounting screws with a screwdriver.
Disconnect the stock voltage regulator from the wiring harness and remove it from the motorcycle. Connect the new, high-output voltage regulator to the wiring harness.
Locate the pair of yellow wires on the stator's wiring harness. Connect a single yellow wire to your headlight's power wire using a butt connector. The remaining yellow wire will not be used.
- "The Professional Motorcycle Repair Program"; Professional Career Development Institute; 1995
- Baja Designs: Enduro Installation (pdf)
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