XR400 wiring walk through for Super Bright LED headlight upgrade (Deep Dive)
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- เผยแพร่เมื่อ 10 ก.พ. 2025
- Thinking about a headlight upgrade? Heres how I did it on a 1998 XR400.
Links below.
I'm currently using a custom stator that is fully wound and has 3 outputs. 2 of them are currently used, and the third is available for more lights or accessories if I choose to add more.
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Components (what I'm currently using) -
Multi-function switch: amzn.to/3dQA6sF
Battery: amzn.to/3s2OwQQ
Capacitor: amzn.to/2VrKYXy
Voltage regulator: amzn.to/31tXTM7
I've currently switched to using the Trail Tech Rectifier/Regulator combo unit instead of a separate rectifier and regulator: amzn.to/2OfGa6J
Light setup used in this video (see below for current setup) -
Nilight 12in light bar: amzn.to/2AewRNP
Nilight row light: amzn.to/3eJ6dM7
Nilight flood: amzn.to/31sFnUH
I've since switched to this beast of a headlight unit -
Squadron LED lights: amzn.to/2BbYaZK
High Output Stator -
amzn.to/31GVCgL
(stator cover gasket) - amzn.to/3f1TqVc
Other Rectifier Options / Regulator Combo units -
amzn.to/31OR6x3
amzn.to/2YY4EV6
amzn.to/3e5qJp7
LED turn signals -
amzn.to/3igIbtN - standard style
amzn.to/3dIt7BT - flexible strip
Accessories -
Heat shrink tubing: amzn.to/2NCfIkf
Wire harness: amzn.to/2YJPyT6
Blinker/flasher for LED lights: amzn.to/2YH0ocg
Solder station: amzn.to/2VtCP4N
Immix Luggage rack: amzn.to/2NWoMk5
FOR INFORMATIONAL PURPOSES ONLY
Dropped my xr400 on the trail one too many times today and all turn signals are dead, one even not on the bike anymore lol. This video is gonna be real handy tomorrow. Thanks for the amount of detail
What a great video. Thank you for taking the time to make it.
Great Information, I'm putting in a new Ricky Stator 200 watt Stator and my bike has the same Baja Designs dual sport kit. I'm in the midst of trying to figure out how to get everything working. This is a big help!!!
Excellent information, question have you seen any being run with everything behind the headlight? So the whole system remains AC just where you would plug the light in then run reg/rec cap/battery all up front after the switch.
I'm looking for a DIY solution for Baja style lights on xlr250r (euro spec) the 30w number plate light is worse than a cheap head torch.
Pondering twin 5 3/4" led ebay units although can't find much for amps draw, they would have the look 👀 and several 1000x better visibility.
I haven’t seen a setup like that personally but it could work depending on battery size. As long as the stator is putting out enough power to run the lights. I’d personally put out the extra cash for Baja Designs or Ruby LED lights as the eBay lights I used weren’t as good. That’s what I finally ended up doing after my eBay specials burned out.
@@MakeFixUpgradeCool I'm thinking it's definitely a non destructive way to test a system, I've seen enough badly butchered vehicle wiring to want to splice in neatly if I have to, but running the whole lot on DC is also a neat solution, just not keen on battery in air box.
I need lights for 95% road use so all the off-road kit is non start, must have high low with a good cut off lots of the 5 3/4" or 7" LED "Harley, classic bike etc" lights have got good reviews just very little information on how much power they actually use to work out a twin Vs single headlight setup with or without stator upgrade.
I'm sure I will be referencing this video more than once before I'm done.
Wow ,so detailed, thanks!
Great video. Just used this on my xr250r
Sweet! Thanks for the feedback, glad you found it useful!
I just got a 2004 xr400 with a baja designs light kit with turn signals, horn, high and low beams, and an acerbis rear add-on fender with brake light and area for tag plate. I want to take it all off and just have a nice LED front light and the original tail light. I scared I’m going to snip or unhook something and kill the bikes electrical system. hope this video will shed some light.
Good luck! If you have any questions let me know. I ended up taking this headlight off and installing a squadron headlight on this bike. If you just want to upgrade the headlight you should be able to determine if your bike is AC/DC lighting and buy the appropriate LED light. The squadron was a simple plug and play install. I bought the DC version because I have the regulator/rectifier on this bike.
Lot's of great info. Unfortunately everyone's bike has been modified differently. I suspect my battery is in poor shape and would like to replace it. The link you give can't be found. Could you recommend another source and give specs? Thanks Chas
I've updated the link in the description to an antigravity battery. Thanks for the heads up! I've had good luck with antigravity batteries so far. I carry one of their jump start packs with me and have used it a few times.
The best video I've seen on the subject, very nice and thank you. Do you feel a Stator upgrade is required to simply run a USB charger(12 volt). That's all I'm really looking to do..
Thank you for the kind feedback! Glad you found it useful. For a charger I'd say it depends on what you want to charge. It may not be necessary for low volt stuff but if you draw too much from the ignition circuit you might end up with unwanted side effects. I think upgrading the stator is good idea and so far all the XR's I've owned have already had it done. I'd go with the trail tech rectifier/regulator combo if you're going to add it as it's the best quality one I've used so far. (link in description)
Great Video, very informative, Thank you!
Thanks! Glad you enjoyed it!
Pro tip : watch series at flixzone. I've been using them for watching all kinds of movies these days.
@Mohammad Castiel Definitely, have been using flixzone for since december myself =)
@Mohammad Castiel Yea, been watching on Flixzone for since december myself :)
I have another question, at minute 8:32, what are the batteries used for? And, what model of batteries are they?, ... and the final question ... if I install a motorcycle battery, would I have to feed it with the 12v output?
From my understanding the batteries help smooth out the power delivery from the stator to the rest of the DC electrical system. The stator outputs AC, and you need a rectifier to convert it to DC. Once converted to DC you need to regulate it with a regulator (some units come as rectifier/regulator combo units) I found the Trail Tech regulator/rectifier combo to be fantastic so far. I'll update the description with a link. I have mine set to about 14V DC output. From there you connect the regulator/rectifier output to the battery as well as your lighting/electrical system. The battery will stay charged off the stator and provide smoother power delivery for the lighting system. You can pick up battery packs like the one in the video here. This one was in the bike when I bought it.
@@MakeFixUpgrade And, would it work without a battery? I'm thinking on doing this mod, but I will use my bike once every month maybe. Any battery would die or reduce its life in those intervals.. I just need a better illumination from it.
@@AlejandroPerezCosio It might work, or you could try a large capacitor instead of a battery. I've let the XR sit for months and never worried about the battery. The bike is kick start and the engine spark runs directly off the stator so the batteries are only ever used to smooth out the power delivery to the headlights/taillights.
@@MakeFixUpgrade I now get it, it's just acting as a kind of resistor for voltage regulation. I have a 86 xr250, I think I will go ahead with this.
Thank you for this great video! the detail you explain with is outstanding!
@makefixupgrade Great video! So I’m doing the same exact thing to my xr400. My question is how does it work having an AC ignition system grounded to the frame and having the DC lighting system grounded to the frame? Any need to float the ground or does this matter?
@Michael I’ve read that it doesn’t matter and in my experimentation I had no issues with it.
@@MakeFixUpgrade thank you for the reply, did you have a special stator in your build?
@Michael I had the 200w Ricky Stator from XR's only.
Very good video!!!!! Fuckin best one I’ve seen! You the man!
Thanks! Glad you like it. I aim to inform. 🙂
Currently doing similar project...XR400R with Rocky Mountain dual sport kit. I’m wiring in a Cyclops H4 headlight in glass lens. Best video I’ve seen on this subject by the way. My question is that it seems like you wired the DC power to the AC tail light. How did that work out? Or did you also upgrade the tail light?
@dlrmon1 I also replaced the tail lights with an LED light setup. Good luck with your project! BTW I found the TrailTech regulator/rectifier combo unit to be the best of all I've tried so far. There's a link in the description if you decide to go with it.
Thanks for the reply...for my XR400R the cyclops light came with it own rectifier...now my stock XR600R I will use you links for a stator and rectifier and a real battery etc. Just because of your attention to detail...Thanks again!
@@dlrmon1 Awesome, thanks for the support! I need to do an updated video on this bike. I put a real battery in it and am running a Squadron headlight on it now. I also removed the accessory lights because I keep breaking them off on harder trails.
Awesome...look forward to your updated video!
Did you wire the pink and yellow wire to the ac dc rectifier?
Yes, I ended up using a rectifier/regulator combo unit from Trail Tech and wired the pink and yellow wires into the voltage input wires on the regulator/rectifier unit.
Hello Sir, I want to put 2 led spot lights on my honda xr600r.
I have 100w stator output . ( ricky stator, 2 ways of 100w each ).
I have a Honda regulator/rectifier from a Honda xr600 European model, I don't know if it's going to get fried because of the 100w stator or not..........
I don't know what capacitor to use.....may be the capacitor is the condenser already with the rectifier....
I heard you mention diodes also......
Is it possible to run the lights without a battery?
I am a little bit lost as you can see.
Please can I ask you about this ?
It's not easy find information of led without batteries on the web.
I couldn't find you on Facebook so I can send a picture of the things I have.
I hope you can help me, thank you very much !
You can run the lights without a battery but the lights will get brighter/dimmer based on the power input from the stator as the engine rpm changes. I'd recommend adding a small 12v battery pack (I like antigravity batteries but any 12v with sufficient amps will work) or using the 4700microfarad 50v capacitor I showed in the video (there's a link in the description) as that will smooth out the power delivery to the light. I don't know if the regulator/rectifier you have will work but I think it should. You can always pick up the trail tech unit I have linked in the description if the one you have doesn't have the capacity.
@@MakeFixUpgrade Thank you very much for your time and knowledge !
Greetings from Ecuador. I want to do the installation that you show in a 2003 xr400r, I want to use the motorcycle for trips at night and at least 5 to 10 hours a day. Would it have a slowdown problem or some other problem? have you had any problems with the installation?
I never had any power issues with this setup. With the way the stator is wound the bike ignition runs off of one winding that is dedicated to the ignition. The lights run off another winding and there's a third spare that I'm not using. However, I modified my setup after this video and replaced the capacitor with a motorcycle battery to help smooth out the power delivery more and reduce headlight flicker. I put a full-size motorcycle battery in the airbag but I think that's overkill. I may switch it out for a more medium size battery or larger capacitor. I also changed the headlight out for a Baja Designs Squadron that I like much more. I found the LED flood light I put on initially spread the light out too much and wasn't as focused directly in front of the bike. I've been planning to do an updated video on it but haven't gotten to it yet. Good luck with your build!
Hi. Thanks for the video. Where can I consult the diagram? Did you do it?
@Jefferson Barrantes you can see the full diagram at the end of the video. It’s at about 20:00 min in.
Great video. Very helpful.
I have a 97 xr400 and am updating an old street legal kit to a new LED kit and some things confused the hell out of me. This helped a lot!
For this installation it is necessary to change the stator first to the one in the description?
It depends on how much load you plan to put on your stator with lights/etc. If you're going to be drawing more power with lights or electrical accessories than your stator will produce you'll need to upgrade.
@@MakeFixUpgrade I understand well. in the case of the wired circuit in this video. did you change the stator?
@@vidaypescadm the previous owner did.
Does the capacitor size cause to flickering?
An adequately sized capacitor will reduce the flickering. It smooths out the electricity flow. It reduces the peaks/valleys of the electrical flow resulting in a smoother power delivery to the lights/etc. A battery will also do this.