I have a fairly heavily modified 2008 WR 450 that has had the Trail Tech electrical system in it since this time last year. I have done in the last year (no bs) over 100 night rides as until very recently I was living in Las Vegas about 5 miles from Thumpertalk.
I started out by installing the electrical system. My stock headlight was much dimmer!I called Justin at Trail Tech and he told me"your light is trying to run off what little AC power is left, hook it up straight to the battery". I did and life was much better.
I around this very same time had bought two of their SCMR16 Helmet lights and had been using them off batteries. I hooked up my first Tether or Pigtail to my WR450 and then my 08 Raptor 700R. Life was much, much better!
Side Note: the odd ball machines not listed by Baja Designs, Trail Tech that you want to put a tether on but can't get an answer-try it! I was able to run the helmet lights off of a 2209 Yamaha XT250, 2008 Yamaha Wolverine 4 x 4 and a 2008 Yamaha WR 250 R without incident. the utility quads and Dual sport bikes apparently have decent electrical systems stock!
I then began to wonder how much faster I would be able to ride if I had this badass helmet light and a much better light on the machines. An incident one night that left me 30 miles from anything with only my stock headlight convinced me more light equals mo better!
I installed the Baja Designs Dablo HID and was amazed at how much better I could see/ride at night! No problems with charging or anything for that matter. The only downfall to this setup was anywhere near a road I felt like I had to turn off both my headlight and I always turn off my helmet light as it is too easy to look at something and bliknd them for 5 minutes! The Diablo has a spot in the lower left corner(looking at the back) of the actual light housing for a little 7watt halogen running light. Problem solved!
I made some money, rode a lot and wanted to try something different/better. Time for the X2! What a great light! You can't beat this for tight stuff! The light pattern is unbelievable! The SC4(flood) draws 40 watts and MR16(spot) draws 30 for a total of 70watts. With the SCMR16 helmet light which draws 30 I am at 100 watts of load plus my ignition, plus my taillight,meter etc. I start having problems despite turning off the SC4 which is rigged as Hibeam on my handlebar switch immediately upon idling and turning everything off and then shutting my motor off etc. According to Justin from trail tech my stator puts out 100 watts "just off idle" and peak is "just over 100watts like 105 or something. Turns out the bike quit charging riding back over Wheeler Pass from Pahrump to Cold Creek Nevada one night last month. I call Justin he tells me how to test the stator. Stator is good!. Must be the battery. Replace the battery, clean the terminals-go riding. few hours later lights won't fire etc. Voltage low.
I go back to camp and tear the bike apart. It turns out the weatherpak coming off the regulator had a bad connection and was a little burnt. A bad connection cause this or max load? I splice in some wire with butt connectors and shrink wrap everything-replace battery again. No problems at all! I think it ws a bad connection. The regulator/Rectifier is a 150watt item. It is only at approximately 70% at 110 watts so it shouldn't be working hard!
I am right now putting the Diablo back on with the 7 watt running light set up as Lo Beam on the handlebar switch and the 35 watt Diablo+the 7 watt running light as Hi Beam on the handlebar switch that puts me at 42 + 30 (Diablo&7 + SCMR16 helmet) which is to reiterate 72 watts. I figure the ignition and taillight etc I have to be around 80 watts of load. At idle I should be drawing a little less than whatever a little less than whatever the system puts out. Remember its 100 watts "a little off idle". With a little prompting I got the Baja Designs guy to say basically the same thing. their systems put out the same wattage they just don't speak the same lingo! Baja designs claims a little more output but WILL not be as optimistic when recomending lights. Trail tech is a little more conservative/realistic with their ratings but will recomend lights that max out their system without reservation and rightfully so. If you don't stop much a 100 watts of lights with their system on a newer WR450 will not be a problem. Just shut some stuff off and then kill the bike! Rmember these HID lights draw a little more than double at startup! Kick the X2 and your helmet light on all at once with the bike off and your hitting the battery with over 200 watts!
There is no way you are going to get the same 100 watts of a Baja Designs regulator/float the ground mod as you will with Trail Techs system. Look at a stock stator. They don't even wind all the poles or whatever they call them. You are getting 40 or 50 watts of DC with that mod max.
Final incarnation: No clutch safety switch, no neutral safety switch, took out a bunch of wires and relays and whatever else. I used one of those two for a hidden anti-theft switch. Works great! Bike will still start with the kick start though. I just ordered 3 AP-2 Auxilary fuse blocks for my machines as I am tired of bumping the handlebar switch and turning my light on and my OCD goes into overdrive and sees the wires and inline fuse holders etc. Here is the link, I'll let you know how it works!
The AP-1 and the AP-2 are dimensionally the same. The AP-2 has the capability for a number of fused auxilary circuits that come on with the main switch via a relay. Both are WATER RESISTANT.
Have a good day.
Trail Tech is awesome! So is BD but I am not as familar with them. Try their flashlight:-)