BDX STAGE 1 and STAGE 2 Electrical Kit Install Guide
A. Getting ready.
1. If you are installing STAGE 2 11-pole stator, disconnect the battery.
8-pole stator install does not require the battery to be disconnected.
Note: A flywheel puller will be needed to remove the stock flywheel. We don't have this item in stock at this time, but a quick search online for "GY6 Flywheel Puller" will yield results.
B. Removing stator.
1. Locate the black cooling shroud covering the cooling fan on the passenger-side of the engine. Remove this cover ([2x] 8mm hex bolts, [2x] 7mm hex screws).
2. Remove fan.
3. Remove flywheel nut. An impact wrench may be needed.
4. Using flywheel puller, remove flywheel.
5. Remove stator assembly and trigger wire pickup. Take note to how the wires are routed under the clamp.
C. Installing the new stator.
1. Install the new stator, route wires under clamp. Do not clamp the wire leading to the trigger wire pickup. Install trigger wire pickup.
2. Position the new flywheel over the stator. Rotate the flywheel until it slides onto the shaft, it's inner magnets should pull it over the stator. Check that no wires are touching the flywheel. Any wires
allowed to touch the flywheel will be frayed and severed within minutes of riding.
3. Re-assemble in reverse order of disassembly.
D. The re-wire for 11-pole stators.
If you are installing a 8-pole stator, please disregard the following instructions.
1. Disconnect original rectifier and cut rectifier plug from away harness. The new rectifier will be wired
in it's place, using a different wiring method.
2. Please refer to attached diagram.
3. Attach the yellow wires from the stator, to the rectifier. They can be used in any arrangement.
4. Attach green from rectifier, to black bundle in the engine wiring harness.
5. Attach red from rectifier, to red bundle in engine wiring harness.
6. Attach green from stator, to black bundle in engine wiring harness.
7. Locate the yellow wire (with red tracer) from the original rectifier plug, and attach it to the red bundle in the engine harness. Make sure your headlights lights are disconnected or they will immediately
start pulling power from the battery.
8. Disconnect the auto choke. Remove purple wire pin from it's plug (using an ice pick or similar tool to press down the pin lock inside the plug). Attach wire from rectifier to purple wire pin, wrap
connection in electrical tape. Re-connect the auto-choke plug (with black wire still in place).
In this system, a switch will need to be used to turn off the headlights when not in use.
F: Problems after installation?
Here are a few specs to help troubleshoot any problems that may occur. Please see below.
11-Pole stator, voltages from stator harness at idle.
With all wiring correctly installed: Attach ground lead of multimeter to the green wire coming from the stator, and the positive meter lead to one of the three yellow wires coming from the stator:
Two of the yellow wires should read: 14vAC - 16vAC
and the third yellow wire should read: 10vAC - 12vAC
11-pole stator Ohm Values.
Same process as above, with the stator harness (3x yellow, 1x green) isolated from the rest of the engine harness- and the meter set to read resistance.
Two of the yellow wires should read: 34.0 ohm - 35.0 ohm
and the third yellow wire should read: 33.0 ohm - 34.0 ohm
