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IT 400 dual sport, 12v electric?

14 Feb 2020 19:03
Dunk
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IT 400 dual sport, 12v electric? #1
I picked up a '77 IT400 last week. Headlight and tail light filaments were blown when I got it. I got new 6v bulbs and the lights work, but inconsistent. Maybe loose connections in wiring or the switches as it's intermittent. The brake light works 100% of the time off a switch in the front brake, but is very dim at idle. Plenty bright at RPM though. As is the lighting it good enough for my immediate use, brief pavement pounding between trails and don't plan to be out after dark.

I would like to have consistently functional and bright lighting suitable for use at night on road though, and add turn signals. Is there a stator or lighting coil available that will get me 12v at idle? I assume I could use any of the typical reg/rect units such as Oregon Motorcycle Parts or cobble my own from digikey or wherever. I'm thinking a quality H4 reflector with an XT500 bucket and brackets would probably fit the IT. For the rear just swap the 6v bulb for a good 12v 1157 style LED. For turn signals I could use an XT500 left control, flasher, and whatever signals I find that mount easily. Beyond that a small battery or capacitor should be easy enough to mount somewhere.

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14 Feb 2020 22:11
trailhand
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IT 400 dual sport, 12v electric? #2
A venerable query....sounds like you no need assistance :)
Nonetheless, once upon a time I used (with light mod) a 6v CT1 Battery holder/holding bracket,
as found beneath the seat of said steed. And I bolted it up, 1 bolt to the front left fuel tank
mount.... ran lines from there, rectifier under seat.... It made nice the 6v system
at the time. More is desired these days no doubt. Enjoy :)

Toby L
Yamaha CT1 175
Yamaha DT1 250
Yamaha RT1 360
04' Yamah XT 225
05' Honda XL 650
99' Suzuki DR 350

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20 Feb 2020 18:39
DirtPirate
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IT 400 dual sport, 12v electric? #3
You can convert the existing lighting coil to 12V. I'm going to do it on my 1979 IT175. There is full 12V conversion thread on the Aussie IT forums, just google it.
I have already sourced the new regulator and bullet connectors needed, very inexpensive to do if you are handy.

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20 Feb 2020 19:37
Dunk
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IT 400 dual sport, 12v electric? #4
I've never rewound a coil or stator before but I'm not opposed to doing it if I have some direction. The Australian IT forum is password protected for everything. I submitted my registration to the yamahait.com.au forum on the 5th and it is still awaiting admin approval. I believe I tried registering years ago as well, when I was considering another IT, and my request was never approved. It was a heck of a struggle for a dumb American to figure out the beer riddle, but I did eventually. In any event, if you know someone over there who can approve my registration request I would greatly appreciate it if you could put in a good word. From the google excepts it seems like a wealth of knowledge.

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21 Feb 2020 19:41
DirtPirate
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IT 400 dual sport, 12v electric? #5
Can't help you with the login, just answer the questions correctly, I know it took a bit of research before I got them all right.

The 12V mod does not require any rewinding, you are only "floating" the ground and adding in a 12V regulator. Even if you do rewind, it won't net you that much, again, plenty of info can be found on that topic.

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07 Mar 2020 21:48
mdscott
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IT 400 dual sport, 12v electric? #6

Dunk wrote: I've never rewound a coil or stator before but I'm not opposed to doing it if I have some direction. The Australian IT forum is password protected for everything. I submitted my registration to the yamahait.com.au forum on the 5th and it is still awaiting admin approval. I believe I tried registering years ago as well, when I was considering another IT, and my request was never approved. It was a heck of a struggle for a dumb American to figure out the beer riddle, but I did eventually. In any event, if you know someone over there who can approve my registration request I would greatly appreciate it if you could put in a good word. From the google excepts it seems like a wealth of knowledge.


I too can't get the yamahait.com.au admin to respond. Markt had to help me with the beer question. :ROFLOL

Thanks Mark
Roseville, Ca.

'76 Bultaco 143 Frontera
'06 GL1800
'01 KDX220
'68 YG5T 80 Trailmaster
74 DT360
75 Norton
73 CB500K
63 C200
87 PW50
64 McClane Edger

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09 Jun 2020 19:26
Dunk
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IT 400 dual sport, 12v electric? #7
I completed the 12v conversion. I used a coil and regulator from Rex's speedshop for a DT400, along with his 12v horn and capacitor. The instructions provided were near useless and did not give a pinout, but rather just wire color to convert a DT to 12v DC.

I also got turn signals, left control switch,H4 reflector, and headlight mounting ears, and kill switch for an XT500 from thevintagespoke.com, LED turn signal bulbs (1156) from superbrightleds.com, and a LED turn signal flasher from amazon.

With all this stuff I had what I needed but had to figure out how to wire it up. The coil from Rex has two taps. One mid coil (yellow) and one full length (green).

Wiring to regulator is as follows:
red is +12v to your battery or capacitor
black is ground to be grounded to frame
White is connected to the green (full winding) on the lighting coil (white to red on regulator has a diode between them)
Yellow is connected to yellow mid coil tap on the lighting coil, this gives you AC regulated to 12v for the headlight

For the XT500 left control switch I did not use several of the wires for on/off. I used Honda style bullet connectors I had on hand and wired it up for headlight always on while running on 12v AC. Tail light on 12v DC always on when running, brake light to the brake switch at front brake. Turn signals tapped to the +12v DC. The Rex coil would run one turn signal fine but not two. After changing to LED bulbs all lights are very bright and function as intended. I used a 35w/35w H4 headlight. Horn is off the horn button on the XT500 switch. Added a kill switch on the bars, though I may add a key switch at some point if I figure a place to mount it.

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