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February 20th, 2006, 03:15 PM   #1
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Long term test up date

When I bought my bike, a 2000 FE400E, used 2 years ago I read about all of the electrical issues that everyone seemed to have with their bikes. So I decided to try a couple of things myself to see if I could improve on the issues that bothered me. First off the original owner said that the stator was the original OEM unit and the only electrical things he did was to remove the keyed on/off switch and he also removed all of the lighting. So I bought a new tailight and headlight and mask.

I wasn't happy with the light that the stock headlight put out so I decided to switch it out in favor of a Baja Designs unit. I installed their KTM light improvement kit part #60-0037. It came with a glass lens to replace the factory plastic one and it was a perfect fit in my OEM mask. It came with a Halogen 80/80 watt H4 bulb. The new set up puts out about 10 times the light that the OEM unit did and it is a much brighter and whiter light. It is much easier to see at night now. I also hooked up the rear light and also hooked up the brake light to the rear brake for night riding.

Also the bike came with the YUSA YTX7L-BS battery so I switched it out with a YUSA YTX9-BS battery. It puts out about .2 more amps. I charged the new battery with an Optimate III charger and I keep it hooked up to the Optimate charger between each ride. Before I changed out the battery I could not start my bike with the electric starter until it was warmed up just like everyone else but since the change it starts on the electric starter on the first try when the weather is warm and on the second or third try when the weather is really cold or the bike is cold. The only other thing I changed was to switch to an irridium spark plug.

I wanted to test it during a couple of cold Chicago winters and with the new lights that put more of a strain on the battery just to make sure before I wrote this. It has been over a year and a half and everything is still operating fine. We even had a week of below zero temps back in December in which I tried starting the bike on the electric starter after the 4th day and it started on the third try. We also had below zero temps over last weekend and the bike started on the electric starter again on the third try after sitting for over a month. The bike still starts off the electric starter when cold.

I hope this helps someone out.

Don
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February 20th, 2006, 07:29 PM   #2
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Re: Long term test up date

I have to change my battery as well, but when i look at the bike i think: how the hell am i going to get the battery out? Is it possible to take it out without cutting the frame?
An also, is it possible to adjust the headlight? when i ride at night, it lights up the sky,and not the road...

cheers
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February 21st, 2006, 01:42 AM   #3
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Re: Long term test up date

It's not an easy task removing the battery. I found the easiest way is to remove the tires mud gaurd and then remove the top bolt of the shock and let it fall against the tire. Then you have to massage it out of it's position removing it from the rear.

As for the headlight, I was not able to adjust the OEM light but the Baja Designs replacement is adjustable. It has a glass lens and it definitely lights up the way a whole lot better. If you want to stick with the factory light you could always cut the masks straps off and then put some type of shim between it's mounting points and then wire tie the mask back on. This way it pushes the top of the mask out aiming the light more towards the ground. My straps kept breaking anyways so I cut the straps off leaving the rubber where it goes through the masks hole. I then drilled a hole just big enough to fit a wire tie through and then I re-mounted it using the said wire ties. It works perfectly and has yet to break in a year and a half.

I hope this helped.

Don
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February 21st, 2006, 02:04 AM   #4
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Re: Long term test up date

look my battery patend in my gallery.it fits on the stock place without cut anything.needs only a diffrent box.it has two more craking amps from stock 2004.it keeps at list 5 years.i had try this battery for 5 years in a yamaha super tenere 750 and then i sell the bike with this battery on.no problem.it turns the husaberg electrik start two times more from stock yuasa 7
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February 21st, 2006, 06:28 AM   #5
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Re: Long term test up date

Originally Posted by SM_Master
is it possible to adjust the headlight? when i ride at night, it lights up the sky,and not the road...
I can see from your avatar why "lighting up the sky" might be a problem. Try keeping the front wheel on the ground. That should help.

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February 21st, 2006, 07:34 AM   #6
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Re: Long term test up date

Originally Posted by SM_Master
I have to change my battery as well, but when i look at the bike i think: how the hell am i going to get the battery out? Is it possible to take it out without cutting the frame?
You need to remove the starter motor, be careful not to break the O ring (good thing I had a spare). You also need to remove the starter motor bracket, and then you should be able to remove the battery, not easily, but you can do it.

Others claim you can also do it by removing the rear shock.

BERGO: the Cyclon battery gives 5.0 Amps, the YTZ 7S gives 6.0 Amps. Are you sure the Cyclon is better?
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February 21st, 2006, 01:07 PM   #7
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Re: Long term test up date

Yes, Nick is right
5.0 ah is less than a YTZ 7
Releasing the top bolt and swinging away the shock is the quickest way to get your batteery out.
Cutting the bottom of your light housing out allows you to angle down your headlight.

Jobs, a gooden !!

Regards
Ady
BTW. Thanks for the info Don. I'm glad all is well for you.
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February 21st, 2006, 05:20 PM   #8
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Re: Long term test up date

Thanks for the info boys!
Can't wait to get the e-start running =)

And to you logjump: il try your advise, at least for a little while, but can't give you any promises
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February 21st, 2006, 05:27 PM   #9
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Re: Long term test up date

Hey Longjump

I just checked out your website, that's some really nice looking furniture that you've made! I noticed that you used a lot of bookmatched quilted and flamed material, it really sets your stuff apart from the rest! I use a lot of the same flamed maple and quilted maple in making electric guitars guitars.

Don
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February 21st, 2006, 05:49 PM   #10
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Re: Long term test up date

i got my battery out on my 04 by removing all the mounting hardware, sliding the battery out of the cage and sliding it out the side. took a few turns, spins, and flips but i got it out. think it came out the right side if i remember correctly. good luck
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