Street Legal XR100R Dirt Bike Build MUST WATCH

If you are looking to make your dirt bike street legal, this is a must watch video. Everything I used is listed below with links. Follow along as I show you in depth how I made my wife’s 2002 Honda XR100R dirt bike Street Legal with 12 volt LED lighting and a 12 volt charging system with battery using a generic Tusk Enduro Lighting Kit. We install the lighting Kit, 12 volt LED lighting, LED headlight bar, battery, hand controls, horn, mirrors, upgraded stator with DC charging circuit, detailed views of wiring everything together including a voltage regulator and rectifier, how to solder, installing a digital speedometer with integrated turn signals and programmable check engine light maintenance meter. What makes this build a little more difficult than most is that this bike came factory with drum brakes so a standard hydraulic pressure switch that was included with the Tusk kit for brake lights is not possible. This also makes mounting a speedometer pickup sensor difficult. I have an easy work around for that also! I HOPE YOU ENJOY!
These are not sponsored videos. I have no control over price. This is what I paid at the time.
Tusk Motorcycle Enduro Lighting Kit with Handguard Turn Signals $207.91
www.ebay.com/itm/334242627831
Drag Specialties Rear Stoplight Switch DS-272100 $12.95
www.ebay.com/itm/353881726711
Clutch and Brake Levers - Cable Operated Clutch & Brake Perch Motorcycle Dirt Bike Moped for Yamaha. The mirrors thread directly into these. These fit the stock Honda bars $17.96
www.ebay.com/itm/401069745423
Mirrors - Pair Universal Motorcycle Motorbike Scooter Rearview Rear View Side Mirrors 10mm - www.ebay.com/itm/353896390232
Headlight - 2pc 7" Ultra-Slim Single Row Off Road CREE LED Light Bar [1530lm] [18W] [IP68 Waterproof] [12V - 24V] Fog/Driving/Work Lights for Trucks ATV Cars - 60 Degrees Flood Light $21.95
amzn.to/3KxWbg9
Voltage Regulator - DEVMO 4 Wires 4 Pins 12V Full Wave Rectifier Voltage Regulator Universal Compatible with Motorcycle Pit Dirt Bike Quad CG125 150 200 250CC Motorbikes ATVs Mopeds Buggy $12.99
amzn.to/3MElhf9
Stator - ElectroSport ESG122 Stator Honda XR100 $73.40
amzn.to/34vxrpB
Graphics Kit
amzn.to/3uuAHhJ
Honda Factory FX 7 ½” Bar Pad
www.ebay.com/itm/191849901904
12 Volt Battery
amzn.to/4buPb1N
Koso DB EX-02 Speedometer - 4.72" W x 0.91" H x 1.57" D BA048001 www.ebay.com/itm/202777807211
Headlight Mounts - Motorcycle 7/8" Handlebar Mirror Mount Holder Clamp Adaptor 8mm Thread For Motorcycles ATV Scooter Black(Pack of 2)
amzn.to/3Su7HPp
Rear Sprocket 36T - JT Sprockets - JTR1214.36 Steel Rear Sprocket, 36T Honda XR70R CRF70F 1997-2012
www.ebay.com/itm/401342401026
Front Sprocket 15T - JT Sprockets 420 Front Sprocket Steel 15 Teeth Natural JTF253.15
www.ebay.com/itm/324017992654
Gold Drive Chain (Cut to 118 links for stock 14T/50T gearing) DID 420 NZ3 Super Non O-Ring Chain 132 Links Gold Honda CRF150R Expert/CRF150R
www.ebay.com/itm/314998088191
Optional:
Motion Pro 08-0026 Flywheel Puller M27X1.0 L.H External Thread $15.99
amzn.to/378a8Tw
M10-1.5 x 16mm Button Head Socket Cap Screws, Stainless Steel 304, Full Thread, Allen Socket Drive, Heavy Duty Machine Hexagon Screw Drive 10 PCS (used to mount the LED headlight L brackets to the mirror clamps) $11.99
amzn.to/3NFwWen
I did not use the mirror or the hydraulic brake switch that came with the Tusk kit. You can get the price just under $300.00 if you keep your original stator and don’t add the voltage regulator. You would need to use the mirror that came with the Tusk kit and don't purchase the flywheel puller. You would need to buy the Tusk Enduro Kit that has the surface mount front blinkers rather than the kit with the integrated handguards.
TIRES:
Kenda K760 Rear Tire - amzn.to/3FOT42a
Kenda K760 Front Tire - amzn.to/3wvnAdk
Tools and Gear I Use:
Alpha Moto Auxilary Fuel Tank amzn.to/3NrvHiO
A typical MotoVated Weekend Adventure
Vessel JIS Screwdriver amzn.to/3s9KRix
Orange Pick Set amzn.to/3CvC9Qr
Motion Pro Cable Luber V3 amzn.to/3fAN5lP
Cable Lube amzn.to/3Ag4doW
Motion Pro Tire Spoons with case amzn.to/3lCBvdS
Vevor 3L Ultrasonic Cleaner amzn.to/3lCvq14
Speed Blaster handheld sandblaster amzn.to/3CkuzYG
Bel-Ray Waterproof Grease amzn.to/3AgQ0bb
APlus Lift Pneumatic Lift Table amzn.to/30cTaiu
My Safety Glasses (12 pack) amzn.to/2H6tdZf
Amp Bluetooth Noise Canceling Hearing Protection amzn.to/34cZciv
1/2" Impact tool: amzn.to/2X7oYC9
1/4" Impact amzn.to/2DcBf0S
FOLLOW ME:
/ motovated207
/ moto-vated-11196305099...

[@ThomperBeThompin]

You have a great channel and I really appreciate all the work you put into these videos. I'm learning probably 20 new things with every vid I watch!

[@MotoVated207]

Thanks man i appreciate it!

[@esmeben]

Cracking vid, very helpful.

[@MotoVated207]

Glad you enjoyed it👍

[@SeanSR]

Really awesome video! Great content, keep it coming.

[@MotoVated207]

@Sean SR thanks man i appreciate it! 👊👍

Awesome video, great instructions, really easy to follow. Also liking the longer format!

[@MotoVated207]

Glad to hear it! Thank you! I've got a couple real good ones coming out this weekend and next

[@joeylopina]

Very clean install. Good job pal. 👏🏽👏🏽

[@MotoVated207]

Thanks 👍

[@twistedvestige]

this video helped me out BIG TIME wiring up my crf100 and i wanted to comment and say thanks for being so thorough!!

[@MotoVated207]

Thats awesome! I'm glad to help!

[@twistedvestige]

@@MotoVated207 i've almost got my bike sorted but im still having a bit of trouble. i sent you an email!

[@joshuaespericueta2474]

Quality work im working on an xr100 and this is a cool idea to do

[@MotoVated207]

Thanks man I appreciate it! Good luck with your project!

[@Storm32171]

Amazing Video, thank you! I'm a female that also owns an '02 XR100 and I love it! Thanks again for the detailed video.

[@MotoVated207]

Glad you liked it! If you decide to go a little bigger I just picked her up a street bike and she loves it. It fits her perfectly. WATCH the series HERE kzbin.info/aero/PLIN6s_PxF9hq43qjYtLnQp2tOQ5akYqux

[@billdeck9766]

I hope you did come back and cleaned the flywheel. I have cleaned customers flywheels due to no spark or very little spark. cleaned them and engine started right up. This video will help me also with my xr100.

[@MotoVated207]

Yah I removed it and cleaned the iside surface and painted the outside surface. It runs like a top. Starts 1st kick every time

[@Nevinhattle]

Nice build

[@MotoVated207]

Thanks! I appreciate it!

[@SHSPVR]

Hi Brandon I realize this is an old video but you should use the correct terminal crimp tool for the job get your self SN-48B or Full Kit Ratcheting Crimping Tool Kit that come with 8 or more different dies.

[@MotoVated207]

What's wrong with the Snap- On crimp tool?

[@SHSPVR]

​@@MotoVated207 Because you use what is called closed barrel crimp tool the tool you're supposed to be using is called an open barrel crimp tool the process on these are completely different on how they make the connection the terminal looks like a U but when using the correct tool it forms a W because the process rolls the two tabs in on it in self making a better secure connection with the wire in two places at some time and outer installation jacket here a video demonstrating this kzbin.info/www/bejne/qJrFnn6Aoc6jo5o

[@SHSPVR]

@@MotoVated207 Because you use what is called closed barrel crimp tool the tool you're supposed to be using is called an open barrel crimp tool the process on these are completely different on how they make the connection the terminal looks like a U but when using the correct tool it forms a W because the process rolls the two tabs on in self making a better secure connection with the wire in two places at some time and outer installation jacket there video demonstrating this

[@philsodowich5237]

I’m having a incredibly hard time getting the rear brake light switch to work. I installed it exactly like you did

[@MotoVated207]

I dont remember doing anything special. If I remember correctly I think I might have shortened the spring a little then bent a little hook on the end. The one Issue I had was the clamp was sliding so I had to go back and tighten it up a little more but other than that it didn't give me any trouble.

[@-iIIiiiiiIiiiiIIIiiIi-]

Wife: "Honey are you done setting up my bike yet?" Husband: No, I still got all this soldering to do..." Wife: *Rolls Eyes*

[@MotoVated207]

Hahahahaha pretty much! I tell her good things come to those who wait LOL

[@c29Mor]

Thanks for the vids, very helpful! Is there any risk to “floating the ground”?

[@MotoVated207]

I'm not really that well versed with this wiring. I had to call the stator manufacturer to make sure I was doing everything correctly.

[@AmericaMarsh]

Great video. I got everything wired up but the regulator is only putting out 8 volts. Any recommendations?

[@MotoVated207]

Hmmmmm. That's weird. It would be hard to diagnose through here. I know I had an issue and had to call the guy I got the stator from and he helped walk me through which wire does what.

[@willoughbooby1815]

Hey I’m making mine road legal could we chat as I need to ask some question about how u got the rear brake light switch set up and couple over bits cheers

[@MotoVated207]

We can. In the meantime make sure you check out the series on this bike because I go into detail on exactly how I setup the reear brake along with all the part numbers and links to order everything I used to build this.

[@gagegage3515]

With the led light you have do u have a high and lo beam setting or is it just one setting for both?

[@MotoVated207]

@gage gage here in Maine we are not required to have a high beam lamp as long as the light gives out an adequate beam allowing you to see at night without blinding oncoming vehicles. This light has only 2 wires, ground and positive so there isnt a way to make it high and low beam. Its just basically on or off.

[@markgreany9562]

how do you know that the voltage regulator will prevent the lithium ion battery from overcharging and bursting into flames under the seat and in between your legs?

[@MotoVated207]

I don't, but if I was worried about getting hurt, I wouldn't be riding a motorcycle either.

[@crazz234]

Couple questions the light bar is only two pin are you not required to have high low? Also the tries are good for road use legally? I'm in NH so I'm sure it's different I read NH is one of the easiest states

[@MotoVated207]

Maine probably has simular rules. The Maine Motor Vehicle Inspection Manual is what I used. I just googled Maine Motor Vehicle Inspection Manual and downloaded it for free. Im sure NH has something simular. Basically the headlight must be of "sufficient power and adjusted to enable the operator to proceed safely under all ordinary conditions of highway weather" so if it's bright enough (within the required candlepower) and aimed properly as discussed within that section of the inspection manual than a seperate high beam is not required. As far as tires, all tires designed for road use will have a DOT stamp. In hindsight I would NOT go with a knobby tire. They look really cool to have knobbies on the street but she only has 260 miles on them and the wear is very noticable. I would go with a dual sport tire like a Michelin Anakee Adventure, or a Shinko 700 or 705 series tire or something simular.

[@crazz234]

Thank you!!! Moto-Vated207!!!

[@crazz234]

@@MotoVated207 just downloaded the manual it's like awesome because only need a head light like you said but also no need for a brake light just a tail? Crazy I'd rather have a brake light

[@MotoVated207]

Thats awesome man! I had a lot of fun building this. I think half of the enjoyment was making it all come together. Enjoy your project buddy!

[@crazz234]

@@MotoVated207 thank you for the inspiration man!!

[@funnifable8]

How did you wire your headlight? What wires did you connect I have a light bar with a red and black (positive/negative) I’m thinking the positive from the light will go to the white wire which is low beam and would the black negative wire go to the black on the control switch?

[@MotoVated207]

This light is bright enough in our state that we do not need to use the high beam side so for this I have the red connected to the positive side of the switch and the black is connected to ground. I'm able to connect the black to chassis ground because I floated the ground on the stator. I'm not sure if I covered that in this video but there is a video where I exaplin that and show how it was done.

[@funnifable8]

@@MotoVated207 I figured it out, I had to do some messing around but got it to work

[@MotoVated207]

Sweet!!!!

[@ytcncgames6552]

How did u get the spedo working cos my one isnt reading speed

[@MotoVated207]

I didn't do anything special. I rigged it up like the directions showed making the bracket that I showed in the video and it works fine.

[@chriscole3672]

Is that new stator able to make it an electric start?

[@MotoVated207]

I would think so. It's putting out almost 14 amps.

[@shane35fowler]

Note to self.... Tiny holes are best 🤔

[@MotoVated207]

Right!

[@shane35fowler]

SERIOUS Question...Why wouldn't Eletrisport set the stator up with the proper harness?

[@MotoVated207]

Great question. It took me a bit to figure out but I will say there customer service is incredible so it wasn't that bad.

[@calsfarm]

I have a Honda xr100r and it will start but when it does I have to use starting fluid also it sounds like the choke is on. Im am wondering how to fix it

[@MotoVated207]

@CAL'S FARM it could be a couple things. The usual culprit is a dirty carburator from stale fuel sitting in the carb. A good carb clean and rebuild usually solves it. The next culprit is lack of compression. This can be caused by worn piston rings or worn valves.

[@calsfarm]

@@MotoVated207 Thank you I ordered a new carb a few days ago anyways. Also I am looking for somegood clutch and break levers for my 2020 honda crf125f I am wordering if you know a good company to get some from.

[@BrandonLund]

@@calsfarm I get pretty much get all of my stuff either from Ebay or Motosport. However, lately I've been noticing that parts are taking considerably longer to arrive than usual so plan accordingly. I've been waiting about 3 weeks for the new sprockets to arrive for the XR

[@calsfarm]

@@MotoVated207 Ok thanks I normally get my stuff from Motorsport too

[@christophercasimir1986]

Some of your links aren’t working anymore 😢

[@MotoVated207]

On the final build episode, I have a list of the things I used along with the price. That way if the link doesn't work, you should be able to search by the description.

[@MotoVated207]

I think I fixed it AND I added more items to the list. If you go into the playlist, I have everthing listed there in the description.