Help! Adding a battery, headlight, and tail light to KLX110

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Help! Adding a battery, headlight, and tail light to KLX110

This is a discussion on Help! Adding a battery, headlight, and tail light to KLX110 within the KLX110, DRZ110, TTR90 forums, part of the General Talk category; I have a 2003 klx110 that I have made street legal. I've added a battery and turn signals, Acerbis Cyclops headlight, tail light, brake switch ...

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  1. #1
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    crxhf20's Avatar

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    Help! Adding a battery, headlight, and tail light to KLX110

    I have a 2003 klx110 that I have made street legal. I've added a battery and turn signals, Acerbis Cyclops headlight, tail light, brake switch and built wiring harness to control it all. I can get everything to work but no matter what I do the bike will not charge the battery if the headlight is on.

    I went from the stator on the White? and yellow wires to a regulator rectifier, and from that to the battery. If I remove the head light from the circuit it will keep the battery? around 12v with just the led tail light and blinkers. If I leave the headlight on it will eventually drain the bike dead even while riding at a decent RPM. You can actually watch voltage slowly drop with a volt meter. I've tried 2 different regulator rectifiers and it still will not work correctly.

    This is the only thing keeping me from ripping up the streets, any help or suggestions are appreciated.
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  2. #2
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    loopiemclooperson's Avatar

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    Does your multi-meter read DC amps? A klx110 stator is capable of 90 watts, which is about 7.5 amps at 12vdc.That will not be at or just off idle either, but higher in the rev range. What is the wattage of your head light?

    Sent from my SCH-I545 using Tapatalk
    Last edited by loopiemclooperson; 04-13-2017 at 12:52 AM.

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    Just noticed that the 06 and up klx110 has a 90 watt stator. Not sure about the 03 it may be less? If you can read the amps in series with the battery that will tell you if you have the capacity to support your current lighting system.

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    Minibikaa's Avatar

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    I couldn't tell from your post... Are you running a switch to the headlight? or is it constantly powered on? Running a switch will allow you to use the headlight only when necessary and will significantly help drain..

    Might want to consider swapping over to LED if the headlight is not already. The reg/rec you installed will allow you to run LED. Less draw and brightness is the same or better..

    Running a capacitor through the power wire going to the headlight may also be something to consider... This wont solve an over capacity problem with the lighting system but will generally help the heavy draw.

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