Harness Stripping for use of pingle tether - Kawasaki KFX450 Forum

Extent Racing 21 · 01-03-2009, 05:35 PM

As many of you already know when you install a regular teather on the KFX's, when the teather is pulled, you need to shut the key off right away or you will blow the stator. The remedy up until now was buying a baldwin setup, which is expensive- i think around 170 dollars or so. Many people have been trying to figure out a way to correct this problem in the harness, well Dave at DRT motorsports has figured it out. He found out how to make a normal teather work without risking damaging your stator, he also can modify/strip down your harness for you. Its done to both my bikes, works kick ass and he really does a great job. I just thought i should give credit where credit is due, also to let you guys know that this can be done. If any of you are interested or have questions about this, call Dave at 603 396 6835 and tell him you heard about this from Brian Daigle

raredirt · 01-05-2009, 12:02 PM

Always nice to share info thanks for that.

On another note I just want to say I have the ProArmor and it is installed with there kit I have came off a few times and had the key in the on postition for sometime (5 - 10 minutes) why the tether was pulled and I have had no issues. Obviously you don't need the install kit for a normally open tether just need to get it hooked up correctly.

Once again thanks for sharing.

Extent Racing 21 · 01-05-2009, 05:22 PM

yes well you would find out though that if you did that a few times you would be replacing your stator, the amount of time your tether was pulled with the key on is about the max allowance before the stator burns out. Ive seen it done with the pro armor tether also, with and without install kits, its just a weired kawi problem, just thought id let people know where they could go, or who to talk to-to get this fixed!

Miles Machine · 01-06-2009, 11:05 AM

What exactly makes the stator go bad, the only thing i can think of is that ur hooking the teather up so that it shorts out the stator which is odiously bad. Any info would be nice.

Thanx

~chad

thomasdjames1 · 01-06-2009, 02:25 PM

QUOTE (Miles Machine @ Jan 6 2009, 11:06 AM)

Quote:

What exactly makes the stator go bad, the only thing i can think of is that ur hooking the teather up so that it shorts out the stator which is odiously bad. Any info would be nice.

Thanx

~chad

I am not exactly sure what causes it either but you must be correct that when pulled off the battery is shorting back through the stator. I have not looked closely at one yet but I am planning on installing one. I am hoping that the key switch only has three wires on it. It is very easy with a relay to make it work how it is built. If the kill switch is an open circuit when the lanyard is in place then use a normally closed relay to correct for that. If you have any questions about how to do that let me know. The only problem I foresee could go wrong is the relay wanting to “bounce” because of the vibration but there are other relays used on the thing.

Extent Racing 21 · 01-06-2009, 05:28 PM

im telling you guys im not crazy, its not a well known problem because not many people will have the key left on with the tether pulled for more than 5 minutes. When you hookup the tether all the different way you are all talking about, it WILL work, but go ahead and try it, but leave the key on for 15 minutes and then try and start it, your stator will be cooked. Many builders including Dave Therrien at DRT tried to figure this problem out for a while, he is Josh Creamers mechanic, and they somehow figured out how to fix it. Hooking up the tether on a KFX isnt the same as hookin it up on any other bike, at least were you wont hurt anything. Its not like all of us fall off and dont turn the key off for 15 minutes, but itl be that one time where your hurt or something, and its left on, then the next time you go to ride you need to replace the stator.

mwca23 · 01-07-2009, 12:14 AM

I used my normally open Pro Armor kill switch to trigger a SPDT Bosch relay to open up the circuit for my factory kill switch which works like a charm.

thomasdjames1 · 01-07-2009, 07:26 AM

QUOTE (mwca23 @ Jan 7 2009, 12:15 AM)

Quote:

I used my normally open Pro Armor kill switch to trigger a SPDT Bosch relay to open up the circuit for my factory kill switch which works like a charm.

Exactly what I am talking about!

All you have to do is find a wire that has to be hot for the bike to run and when you flip the switch to off it goes dead; then take a relay and make that happen as you have done, it will work fine. I would suspect that the key switch and thumb switch are both that way. I suspect when most people are having a problem is that they are using the normally open kill switch as a short to ground when the lanyard is pulled(kill switch goes closed). Therefore making a lot of current flow but it will cut the bike off. I have seen some people recommend using this technique and shorting the coil wire to ground which I would not do. You could also short any wire that has to be hot for the bike to run but this is a bad idea. Use a relay. I am not sure if the key switch, thumb switch, or roll over sensor will be easier to get to but it is not a hard problem to solve. All you are doing is using a relay to make a normally open circuit a normally closed circuit.

Miles Machine · 01-08-2009, 10:14 PM

in that case couldn't you get a normally closed tether and hook it inline with a circuit that needs power, say the switched hot from the key to the ECU to cut ignition spark??

thomasdjames1 · 01-09-2009, 12:32 AM

QUOTE (Miles Machine @ Jan 8 2009, 10:15 PM)

Quote:

in that case couldn't you get a normally closed tether and hook it inline with a circuit that needs power, say the switched hot from the key to the ECU to cut ignition spark??

If you could find a normally closed teather that would work great but I can not find one. I am about to order a teather in the next few days and build a relay circuit for it. I will do some testing and let everyone know if mines works as I think it should. I might sell a few on here for a small amount if anyone wants a kits let me know. I did go to school for 4 years for electrical engineering and now work as engineer in the nuclear power buss.

01-03-2009, 05:35 PM	#1 (permalink)
Extent Racing 21 Member Join Date: May 2008 Posts: 66	As many of you already know when you install a regular teather on the KFX's, when the teather is pulled, you need to shut the key off right away or you will blow the stator. The remedy up until now was buying a baldwin setup, which is expensive- i think around 170 dollars or so. Many people have been trying to figure out a way to correct this problem in the harness, well Dave at DRT motorsports has figured it out. He found out how to make a normal teather work without risking damaging your stator, he also can modify/strip down your harness for you. Its done to both my bikes, works kick ass and he really does a great job. I just thought i should give credit where credit is due, also to let you guys know that this can be done. If any of you are interested or have questions about this, call Dave at 603 396 6835 and tell him you heard about this from Brian Daigle

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01-05-2009, 12:02 PM	#2 (permalink)
raredirt Senior Member Join Date: Jan 2008 Posts: 109	Always nice to share info thanks for that. On another note I just want to say I have the ProArmor and it is installed with there kit I have came off a few times and had the key in the on postition for sometime (5 - 10 minutes) why the tether was pulled and I have had no issues. Obviously you don't need the install kit for a normally open tether just need to get it hooked up correctly. Once again thanks for sharing.

01-05-2009, 05:22 PM	#3 (permalink)
Extent Racing 21 Member Join Date: May 2008 Posts: 66	yes well you would find out though that if you did that a few times you would be replacing your stator, the amount of time your tether was pulled with the key on is about the max allowance before the stator burns out. Ive seen it done with the pro armor tether also, with and without install kits, its just a weired kawi problem, just thought id let people know where they could go, or who to talk to-to get this fixed!

01-06-2009, 11:05 AM	#4 (permalink)
Miles Machine Junior Member Join Date: Mar 2007 Posts: 6	What exactly makes the stator go bad, the only thing i can think of is that ur hooking the teather up so that it shorts out the stator which is odiously bad. Any info would be nice. Thanx ~chad

01-06-2009, 05:28 PM	#6 (permalink)
Extent Racing 21 Member Join Date: May 2008 Posts: 66	im telling you guys im not crazy, its not a well known problem because not many people will have the key left on with the tether pulled for more than 5 minutes. When you hookup the tether all the different way you are all talking about, it WILL work, but go ahead and try it, but leave the key on for 15 minutes and then try and start it, your stator will be cooked. Many builders including Dave Therrien at DRT tried to figure this problem out for a while, he is Josh Creamers mechanic, and they somehow figured out how to fix it. Hooking up the tether on a KFX isnt the same as hookin it up on any other bike, at least were you wont hurt anything. Its not like all of us fall off and dont turn the key off for 15 minutes, but itl be that one time where your hurt or something, and its left on, then the next time you go to ride you need to replace the stator.

01-07-2009, 12:14 AM	#7 (permalink)
mwca23 Junior Member Join Date: Apr 2008 Posts: 5	I used my normally open Pro Armor kill switch to trigger a SPDT Bosch relay to open up the circuit for my factory kill switch which works like a charm.

01-08-2009, 10:14 PM	#9 (permalink)
Miles Machine Junior Member Join Date: Mar 2007 Posts: 6	in that case couldn't you get a normally closed tether and hook it inline with a circuit that needs power, say the switched hot from the key to the ECU to cut ignition spark??