Lighting coil re-wind

[gregp]

Last weekend, I had the opportunity to attempt to re-wind the lighting coil on my KDX200. I had done a little bit of reading on the subject, and I was a bit nervous about it. I bought a spool of 18 gauge magnet wire and had at it. The reason that I wanted to do this was that I am running all of the street legal hardware required for an inspection - directionals front and back, high and low beam headlight (35/35w for now), brake and tail lights (w/front and rear switches), and a horn and a high beam indicator - all with no battery. The stock coil is only good for 50 watts or so, and I had to run a very low wattage tail/brake LED bulb to get everything to work. Even then, things barely lit up and would flash or dim with the directionals.
The re-wind was fairly easy to do, and it took me about an hour. At first, I over wound it, and the coils hit the inner flywheel hub, so I had to remove a full layer. It seems to have worked, though. I was able to go back to a standard 1157 tail/brake bulb - and it is very bright. Everything else works great now as well. I still want to try a 55/60 watt headlight, but I have not done that yet...

[gt_pedaler]

A low power option is LEDs. you may have to install a rectifier if it isn't DC yet but they sip power and are bright. My rear tail/brake buls is a modified 1157 LED from Autozone. Just cut away the socket mounting and wired it up. Then I potted it in clear epoxy to make it water proof. lotsa light, very little heat and it all fits under the tail light lens on the XR.

[breakdirt916]

awesome work greg, I've read about self-winding, and I understand the theory, but always was afraid of trying...I always figured I'd mess it up!

so...now it's time to hook up some heated grips for iccccceee??

[gregp]

I doubt that I have enough current for heated anything, but I do now have great lighting, all around. The stock coil is just enough to power the 35 w headlight, the small tail light, and nothing else! Now, everything works as it should.

[gadget]

Pretty impressive!

[Chippertheripper]

Link up some good info, if you would...

[gregp]

http://www.thumpertalk.com/topic/859...rewind-how-to/

[gregp]

The OP used 17 gauge, I used 18 gauge. Like many folks, I was afraid to start this project - once you snip that wire, there is no turning back! When I was done, I couldn't believe how easy it was, and that I hadn't done this earlier.

[csmutty]

Good thread! Ill have to do this with the kx100!

[gregp]

Your KX100 has a lighting coil?