A Yamaha YZ-250 dirt bike is designed primarily for motocross racing, sacrificing amenities such as lighting for a lower overall weight. While beneficial on a racetrack, riding a YZ-250 on an open trail can make most riders nervous once the sun sets. While adding lights to the motorcycle may sound easy, the YZ-250's stock electrical system will require some modifications before it can adequately power both the lights and the ignition system. You may want to have the work performed by a qualified Yamaha technician as this project does require a certain level of familiarity with your motorcycle's motor and electrical system.
- Skill level:
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Things you need
- Oil pan
- Socket wrench
- 10, 14 and 17mm sockets
- External stator kit
- Wire cutters
- Electrical tape
- Nylon cable ties
- T-tap electrical connector
- Motor oil
- Headlight kit
- Electrical butt connector
Drain the motor's oil supply into an oil pan using a 14mm socket to remove the drain bolt from the bottom of the motor. Using a 10mm socket, remove the bolts along the motor's left side cover. Pull the cover and stator assembly away from the motor to access the flywheel. Remove the flywheel nut and washer with a 17mm socket.
Mount the external stator kit's magnet assembly over the flywheel, facing the magnet's finned surface away from the flywheel. Secure the magnet in place using the new washer and flywheel nut provided in the kit. Tighten the nut with the 17mm socket.
Install the kit's replacement left side cover and stator onto the motor, using the 10mm socket to insert and tighten the bolts around the cover's perimeter.
Locate the stator's wiring on the left side cover; there should be a pair of yellow wires and a single pink wire. Connect the pink wire to a bolt on the motorcycle's frame or motor to create an electrical ground for the stator.
Route a single yellow wire along the frame and up to the headlight; this will serve as the headlight power wire. Cut the remaining yellow wire with wire cutters and seal its end with electrical tape. This wire will not be used. Secure the wire to the motorcycle's frame using nylon cable ties.
Use a T-tap electrical connector to splice the yellow wire from the external stator kit's AC regulator into the headlight's power wire. Connect the AC regulator's brown wire to a bolt on the chassis or motor to create an electrical ground.
Remove the front number plate from the handlebars. Unfasten the plastic strap from the number plate and unwrap it from the handlebar. Using the 10mm socket, remove the bolt that secures the number plate to the upper steering yoke. Pull the number plate away from the motorcycle.
Mount the headlight, wrapping the headlight kit's rubber straps around the front forks. Fasten the ends of the straps over the mounting hooks at the base of the headlight.
Connect the yellow power wire from the stator to the headlight's yellow wire using an electrical butt connector. Connect the headlight's black wire to a bolt on the motorcycle's frame to create an electrical ground.
Start the motorcycle to test the headlight. Check that all wire and ground connections are securely fastened if the headlight does not illuminate.
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