KLX 250 Lighting coil - Is there a way to upgrade it?

[farmer58za]

There is only one 6V lighting coil on the '79 KLX. Is there a way to uprate the coil to a higher wattage or introduce a 2nd winding on the same coil?
Thanks
David

[Colin Jay]

Give Steve at Betta Bikes (http://bettabikes.com/) a call, he has been doing the electrical upgrades for the bikes used for reliability trials here in SA for a long time, and I would dare to say that he has probably done 12v upgrades for the KLX.

[TT5 Matt]

I remember a Vic coil winder on the IT Yamaha forum saying to go from 6v to 12v was just a matter of doubling the turns count and halveing the wire size of the old 6v lighting coil.stores like jaycar carry a lot of wire sizes or try motor rewinders.although abit messy a brush of adaldite between layers as your winding the wire on helps with vibration rub between the turns of wire and increases the life of the coil as well

[grouty]

The later KL250 trail bikes were 12 volt. The coils are a direct swap with the back plate. Some re-wiring may be required, and a new 12 volt battery. Not sure if they were about in Oz, but we had them here in the UK. I've not bothered with mine as I have little intention of using it in the dark. Those few occasions I have, it's been a lot of fun with a 6 volt glow worm 

[farmer58za]

I looked at a pic of the 1979/1980 KL 250 coil and it has 2 windings which is much better, even with 6V. That would mean if it fitted, I could use one winding for the brake light only and forget about a battery.

However, that KL coil looks a lot fatter than the KLX one. Grouty, can you confirm that it's a straight bolt-in swop?

Regards
David

[grouty]

Just had another look, and I was wrong. It is the KZ250 road bike that has the 12 volt system. I think I have one of these engines somewhere. If I can find it I will pull the flywheel cover and see.
It will need the CDI box and associated ignition parts to work. The engine cases are the same in that area, although they have a large lump at the front for the leccy start. No ... before you ask .... this engine won't fit in the KLX frame.

[LWC82PE]

Like Colin says, worthwhile contacting Betta Bikes. I have an article on rewinding your own coils that may be of interest to you. Its from 1977 and uses a PE250 as the example but the basic principles could be applied to others.

Power Dynamo do a system for the KL. Link to product info did not work for me so you may have to send them an email

http://www.powerdynamo.biz/deu/systems/lists/kawasaki.php

[grouty]

The kit (78 57 999 00) for the KL250 (1981) is listed as 'No longer available'. Has been for a while.
Shame, as that would have solved every ones problem.

[James P]

Steve at Betta Bikes rewound my Suzuki PE250B stator lighting coils (normally two separate 6V coils; one for stop light, one for everything else) to make them identical and they are now connected in series for a single-wire 12V output. Steve claims 60W output for this set-up. The lighting system is now 12V AC (no battery), but I do have a regulator connected to make sure the voltage doesn't get too high.
I daresay you could obtain a similar service elsewhere, but I generally prefer to use people with bike-related experience.

Regards,
James

[farmer58za]

A lot of the specific bike interest forums have migrated to FB. I posted the same query on the Vintage Japanese Motorcycle Club (UK) page and with a bit of work, actually got the KLX lights to work better, with simply a 12V AC regulator and 12V bulbs. check it out here:

https://www.facebook.com/groups/vjmcuk/permalink/952333461585615/

Regards
David

The kit (78 57 999 00) for the KL250 (1981) is listed as 'No longer available'. Has been for a while.
Shame, as that would have solved every ones problem.

[dont]

A lot of the specific bike interest forums have migrated to FB. I posted the same query on the Vintage Japanese Motorcycle Club (UK) page and with a bit of work, actually got the KLX lights to work better, with simply a 12V AC regulator and 12V bulbs. check it out here:

https://www.facebook.com/groups/vjmcuk/permalink/952333461585615/

Regards
David

The kit (78 57 999 00) for the KL250 (1981) is listed as 'No longer available'. Has been for a while.
Shame, as that would have solved every ones problem.

I think you need to belong to the facebook group to read the post?

[pokey]

Thought about tackling the issue from the other end? LEDs use much less juice

[farmer58za]

Correct, the LED option appears to be the way to go. However, they need DC or must be wired up with capacitors and diodes for AC. That is the next phase of the project.

Right now, A 12V AC regulator, 25W/25W headlight and 5/21W tail light gives great results. Voltage at idle is 9.5V, rising to a maximum of 12 with increased revs.

Regards
David

[pokey]

I was thinking a 6V reg/rec rather than changing stator. Only the tail and Headlight need to go via the reg/rec and with the tail taking SFA juice the rest can be fed to the Headlight LEDS. There are some okay 6V Japanese LEDs I have seen that could be converted to fit the existing headlight housing. Indicators and Horn can remain AC. Thats the way i am going with a current project with a Large Capacitor instead of a battery.

 You can also rewind the existing coils with twice the length x Half the diameter to achive the 12v output. Atleast you will know it fits.

[farmer58za]

Here's a new LED development from the re-formed Preston Petty Products. Sorry, it's a FB page:

https://www.facebook.com/prestonpettyproduct/posts/1501791529966380

Regards
David