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converting a 2003 KTM 525 SX to a Dual-Sport

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Hi I just purchased a 2003 KTM 525 SX and am trying to do a few things, and all the info I'm finding is a bit confusing.

I need to find the cheapest and best way to supply power for all the electric systems short of a starter. (2002 stator & fly wheel or upgraded stator and rectifier for the 03 fly wheel.)

Also a parts list or link on what i need for a 6 speed conversion. (Found alot on this subject but no legitimate list that i could find or how to's)

I already have the lights (front and rear) horn and brake light switches. Just trying to make it all work together reliably, any help is much appreciated. Never done a build were I have to piece parts together like this.

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Check the Trail Tech or Baja Designs websites.  They have the stator/rewind kits needed most of the time.  You will need some sort of rectifier to convert so the headlight/taillight can run.

 

Baja Designs has one kit (universal) that has the battery and all the components mounted on the headlight.

 

As far as the 6 speed conversion, you will have to check with the KTM specialists.  I would think the individual costs and work would be prohibitive.  (Unless you had a parts motor with all the pieces already, you are basically overhauling the full motor, no reason to change or add gears if you don't make sure everything else there is in proper shape).  Otherwise, just change your gearing.  Then you still have the 19" back wheel, again, not optimal but useable and limited to some offroad tire choices vs MX.

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