Site hosted by Angelfire.com: Build your free website today!

Electrical

OEM weak, I have heard estimates of between 100 - 135 watts maximum output. I have also heard the wiring can barely handle the stock electrical loads.
 

Lighting Improvements

Yea, yea, we all know. Waaaa waaaa waaaa! My headlight needs to be brighter. Well get a car then. If that is not a viable option, perhaps one of the following items may resolve your lighting trauma. I urge you to check out Daniel Stern Lighting for info on various lighting methods, and their costs and benefits.

Baja Designs and Casper's Electronics both produce High Intensity Discharge (HID) lighting conversion kits that utilize the standard H-4 headlamp socket. HID lighting offers superior lighting at a lower amperage cost. Tastes great and less filling! Baja Designs ran a bike equipped wih HID lighting in the 98 Baja 1000, so I am fairly confident the lighting system can handle the vibration and shock delivered in dual sport riding. Daniel Stern Lighting has concerns about HID conversion kits, check it out.

A more cost-effective solution to improved lighting is available from PIAA . They have standard H-4 bulbs with some type of magical technology that results in much improved lighting, or so states the claims (Splitfire anyone? ;)). Daniel Stern Lighting has concerns about the claims and effectiveness of these bulbs, check it out.

You can add more bulbs if so desired. PIAA offers many options for auxiliary lighting. Check out CBT Imports for custom mounting kits (for BMW's :(), and useful info on each PIAA model.

Saeng Night Cutters are a great option. They offer multiple mounting options. I have heard only positive feedback about this lighting system.


Motolight offers an unusual fork-mount lighting system. I really like this system for the KLR, or any long-travel bike because the aim of the light is consistent, regardless of front-end dive. Slam on the brakes on your KLR at night and you end up illuminating a very small spot on the road just in front of your front tire, and not much more. There are downsides to this mounting system (ain't there always). One is cost, the Motolight system retails for $245. A second downside is during off-road riding through brush or rocky areas, the lights are exposed to great risk of damage or destruction.

Xenon light bulbs? I suggest checking out the analysis of these bulbs by David Harrison.

Super Battery???

In the Up to Speed column in the January, 1999 issue of Motorcyclist magazine, new battery technology is on the horizon and approaching fast. Much smaller and lighter sealed units. Motorcyclist stated they will be performing a full review in an upcoming issue. I did some poking around on the net, and this looks for real. Keep your eyes open! Bolder Technologies has limited info and product availability. It is now December, 1999, and I don't recall seeing any review from Motorcyclist magazine. House of Batteries appears to be a source, check it out for yourself.

Charging System Improvement

In my search to obtain additional electrical output, I was warned the stock voltage regulator can not handle much more than the stock output of the alternator. The KLR charging system uses a fixed magnet. The electrical output of the charging system is entirely dependent upon the rpm of the engine. The stock voltage regulator grounds excessive charge that exceeds ~14 volts or so. Obviously, this produces a lot of heat. This is why there are heat sinks on the regulator. If the electrical output is increased significantly, the regulator would build up more heat than it was designed for when dealing with minimal drain of the system.
I found a company with an excellent informative website, Electrex USA . They produce regulator/rectifiers and stators. They currently offer a regulator/rectifier for the KLR 650 that can handle 300 watts at a price of $120. Check out Carl Shoup or Baja Designs to re-work your stator for additional output, but I strongly urge first purchasing a regulator/rectifier that can handle the additional load. Fred recommends this shop for stator rewinds:
Carl Shoup
Shoup Enterprise
3172 Glendam Dr.
Grand Junction, Co. 81504
(970) 434-0906