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So
you want your 50(or 70) to have lights, eh? Ok, here is the
skinny.
First
of all I'd like to say that I got most of the info for this
install from here.
It's an install for xr80's and 100's but its very similar to
the 50/70.
Parts/Tools
List
-Flywheel
puller (beatrice cycle sells
them)
-Strap
wrench
-misc.
sockets
-18
gauge magnet wire (google search will yield several places that
sell it, 1 lb. should be more than enough. Places such as this)
-switch(spst
variety)
-12v
regulator (this
is the one I got, $14)
-misc.
wire
-headlight
of your choosing
-Soldering
iron and solder
Step
One
Remove
your flywheel cover.
Step
Two
Remove
the 14mm flywheel nut and its washer. Use a strap wrench to
keep the flywheel from spinning.
Step
Three
Remove
your flywheel using the flywheel puller. The threads on the
puller are very fine so be careful, they are also reverse threaded
so its lefty-tighty! Thread the outer portion of the puller
on, then holding it with a wrench screw in the center portion
to remove the flywheel.
Step
Four
Remove
the stock stator by unbolting the bolts circled in blue. Also
you'll need to disconnect the 2 stator wires from the wiring
harness. All the connectors are different so when you wire it
back up later there is no confusion.
Step
Five
Rewind
your stator using the magnet wire. Wrap the first bare stator
arm with 65 turns of the wire(you could do less, but you'll
make less power), then move to the next arm and go the opposite
direction. Wrap all bare arms in this manner, insuring you alternate
directions on each one. Just to clarify, you will use one continuous
piece of the magnet wire to do the whole stator.
Step
Six
You'll
need to solder your starting point of the magnet wire to the
grounding strap. The ending portion of your magnet wire you'll
solder to an unused terminal. This unused terminal is also where
you'll solder your power wire. The finished product looks like
this.
Here
is a close up of the rewound stator. The blue circles again
indicate the bolts you'll need to put back in place for mounting,
do NOT overtighen these bolts as the holes are easily stripped.
The red circles include the soldering points I refered to as
well as the route the new power line will take out of the flywheel
cover(see how its tucked in with the stock wiring). Notice I
also circled a point of stock wiring. I had to unsolder this
point in order to wrap the last arm of the stator, then I resolder
it. You might be able to work around this without resoldering,
as in anything your mileage may vary. (make sure you
replace the 2 wires from the stator in the wiring harness or
the bike won't start!!)
Step
Seven
Replace
your flywheel, be sure to torque to spec. Replace your flywheel
cover as well. Now you can use your now power wire coming out
of your stator to power your new headlights(or other 12v items).
Refer to this simple diagram for how to wire properly with the
regulator in the mix(this is key so you dont send your lights
something like 40v).
Step
Eight
Mount
the light or lights you picked up and wire them into your new
circuit.
Here
they are turned on
You
can even get creative with your new power source and do tail
lights.
Well
there you have it, your 50 now has lights for those night time
excursions. Be sure to wire the switch into the mix. This will
allow you to turn them off during the day. If you run them nonstop
not only is it not worth it, but you'll wear your regulator
out sooner. It also allows you to go stealth mode at night,
wink wink.
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