Honda XR400 Headlight Upgrade Super Bright LED with Voltage Regulator

I recently upgraded the headlights on my 98 XR400 for easier night riding.
This involved adding a capacitor to smooth out the incoming DC from the rectified AC voltage from the stator as well as a voltage regulator to limit the voltage to 13.5 volts to keep my headlights from burning out.
Paid links:
(As an Amazon Associate I earn from qualifying purchases. Meaning, if you make a purchase using these links I receive a commission from Amazon for referring you.)
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small fog lights: amzn.to/2HqtB2b
large fog lights: amzn.to/2U3JxML
regulator: amzn.to/2TmOnIE
regulator/rectifier combo: amzn.to/356eRRB
capacitor: amzn.to/2ZAu3W5
For informational purposes only.
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[@keithchoe2049]

Looks great. Where did you get the mounting bar?

[@MakeFixUpgrade]

Thanks, I made it. The mounting brackets are short angle and the hoop is 1/2in tubing.

[@lukesancasciani]

Hi do you have a link to the mounting brackets or how you made them?

[@nvmcrider8475]

How did the fog lights work? I noticed you switched to a light bar, is the light bar better?

[@MakeFixUpgrade]

NVMCRIDER I actually prefer the fog lights. They’re a little more focused than the light bar. The main light is also a little too much of a flood light. The current setup will change again as I’m always experimenting to find a better setup. I have a Tansoren brand LED setup on my bicycle that’s really bright with a small battery pack. I’m thinking about buying 4 of them and trying a quad setup on the XR and wiring them directly in. They have a small form factor and I think they’d be perfect for this.

[@kushtrimlatifi6757]

Would you consider building me a light mount? Obviously I would pay for you it.

[@jimarmbrester1721]

Any chance of you doing a wiring diagram of your setup?

[@MakeFixUpgrade]

@Jim Armbrester I don't have a diagram but I'll draw up the basics and make a detail video about it so watch for that. The wiring harness/kit was a Baja Designs light kit that was added long before I got it. The headlight went out and the shroud was cracked so I took it off and used the same wiring to power mine. Aside from the regulator setup I added.

[@jimarmbrester1721]

CrushingDemons Cool, sounds good! I’m looking to do the same in the near future. I could probably figure everything out, but have never wired a rectifier or voltage regulator. I’m watching your video a second time, and I’m picking up a little more than the first time around

[@jasuscaredo]

Dear Sir. First of all, thanks for sharing your video. One question: are you putting together ac ground ans dc ground?? EDIT: Forget my question...Can you provide rectifier specs, please?

[@MakeFixUpgrade]

I don't have specs for it, sorry. It was on the bike when I got it. I can't see any markings on it either.

[@rhiekel]

Not sure why you would set up a discrete regulator and rectifier. I just finished setting my xr400 as electric start . Just ran the single phase stator output to a regular motorcycle rectifier/regular, and use a small lithium battery. System works perfect .

[@sucioslife6214]

Would I be able to run just one led light off a stock stator? 2005 crf450r

[@MakeFixUpgrade]

That would depend on how large of a light you wanted to run. Stators generate AC electricity, if you want to run LED lighting you'll need to convert it to DC with the use of a rectifier/regulator. (I like the Trail Tech combined units) If you pull current from the main stator winding then you could potentially end up with insufficient electricity for spark. If you want to run a headlight you really should have a stator with another winding. I believe the 450x models have a stator with additional winding(s) but not entirely sure. Stators generally are not super expensive. I'd suggest if you want to add a light then upgrade your stator so you don't end up overloading the system. I think changing the stator may also require updating the flywheel as the flywheels designed for lighting have stronger magnets. Trail Tech makes some good units, I've also heard good things about Trick Dual Sport but have no personal experience with their kits.

[@protectork9831]

Could you please make a step by step video on how to from scratch . For us all dummies

[@MakeFixUpgrade]

@ProtectorK9 I've changed the system and put a new Baja Designs Squadron headlight since I made this video. I installed a new larger lithium battery under the seat and put in a new TrailTech regulator/rectifier combo. The battery helps keep the light from flickering but is probably overkill. I'll see if I can make a new video on the setup. The new setup is a lot simpler.

[@protectork9831]

@@MakeFixUpgrade thanks man that would be great. Specially step by step guide

[@project4stroke876]

@@MakeFixUpgrade Ive done this I added a ac to dc rectifier then I put in a led light and it blew the light? But then I was told I NEED the battery to keep it at 12v?

[@MakeFixUpgrade]

@@project4stroke876 you need a voltage regulator to keep it at 12v. I've updated the links in the description and added a regulator/rectifier combo that does both and updated the link for the regulator. A battery will help keep the light from flickering. A rectifier only converts the AC to DC but you can still get voltage spikes up around 25v which will blow the LED light. (I did the same thing to mine when the cheap regulator I used failed. The updated link in the description is a better quality unit.)

[@project4stroke876]

@@MakeFixUpgrade Thanks