DC Super V3 Kit Documentation
1. Warnings and Disclaimers
This guide is provided for informational purposes only and is not intended to be a comprehensive list of all potential failure modes, issues, or risks associated with this product. Users are expected to exercise good judgment, conduct thorough testing, and regularly monitor their system to ensure safe and proper operation.
If you are uncertain or experience any unexpected behavior with your specific equipment, it is your responsibility to consult a qualified professional. Any advice or information provided by the manufacturer or seller is general in nature and should not be interpreted as expert or specialized guidance. The end user assumes full responsibility for the safe and appropriate usage of the product.
Risk of Fire and Equipment Damage Warning:
2. Quick Install Information (Cheat Sheet)
-
Connecting Your 12V Lights and Accessories:
After routing your new Super V3 harness, you will find a white and black pair of wires at the dash, and a second pair at the rear of the vehicle. These are your hookups for 12V lights and accessories. They are dual female 4mm bullet terminals to make connection universal and simple.
⚠️ Important! Any device powered by the white wire (+12V DC, on with the key) must be grounded to the accompanying black wire (DC ground) in the harness. -
Proper Grounding
-
Connect the Negative Battery Cable to the Engine Crankcase:
Always connect your negative battery cable directly to the engine crankcase.- DO NOT connect it to the frame.
-
Failure to do so will result in immediate damage to your stator ground wire upon the first engine start, potentially leading to costly repairs.
-
Do Not Ground Accessories to the Frame:
Grounding accessories to the frame will cause unpredictable or damaging behavior.- Some online sources may suggest that frame grounds are acceptable, but these methods are unreliable.
- Frequent issues such as “checking your grounds” often arise, indicating that these alternative methods are prone to failure.
-
Use the Black Wire for DC Ground:
With the V3 system, grounding is simplified—always use the black wire in the harness as the ground for your 12V DC loads. Black wires are located right next to the white wires used for 12V power. This design ensures reliability and ease of use.
-
-
Current and Wire Capacity:
Ensure the current draw of your devices does not exceed the ampacity rating of the 16-gauge wire, especially considering your local conditions and hot ambient temperatures. -
Key Switch Connections
- Red: Constant 12V. Do not use red for accessories!
- Grey: Main Relay Control. Do not use grey for accessories!
- Blue: Solenoid Control.
-
Kill Switch Functionality
The engine is killed by shorting the trigger sensor to ground, preventing spark from being generated.
-
Fusing
Fuses are 10A by default. Do not increase fuse size unless you understand and accept the risks associated. Replacements are "ATC" blade style fuses. Do not insert fuses at an angle, you will bend the internal pins.
3. Understand the 3-Phase Charging System
Specifications
- Charging Voltage: 13.5V - 14.5V under saturation
- Current Output: 12.5A (at 13.0V)
- Power Rating: 160W
This system is designed to provide efficient and stable power for your vehicle, ensuring reliable charging even under load. It utilizes a three-phase charging system, which delivers consistent energy to the battery and accessories, while offering a buffer to maintain a positive charge rate. Below are frequently asked questions and some key guidelines to help you get the most out of this system.
4. Frequently Asked Questions
-
Will the battery still charge at full rated load (160W)?
Yes, the battery will still charge at full load. Lead-acid batteries are considered fully charged at 12.75V. Since the system operates at 13.0V, this provides a slight buffer to maintain a positive charge rate even at full accessory load. However, please note that under full load, the battery charging will be at a trickle. To ensure longevity and performance, it’s good practice to derate maximums when planning your electrical needs for this system.
It is advised to derate the system when planning your loads. Do not rely on the system's full power rating for long durations, to avoid over-stressing the related components.
-
Will this work with my original GY6 wiring harness?
Yes, the system is fully compatible with the original GY6 wiring harness. The included no-rewire adapter handles all of the charging wiring, allowing you to leave your original connectors unplugged and safely tucked away.
-
Will I need to rewire my headlights?
Not in most cases. The built-in main relay included in this system handles this rewiring for you. It includes a 30A dedicated lighting relay to safely switch the maximum output from the stator upgrade.
Note: If you add an on/off switch, you should always ensure a minimum safe load on the system to prevent possible regulator or stator overheating, or even fire in extreme cases.
-
Can I run LED lights?
Yes, the DC V3 kit is directly compatible with LED lights! Use the white and black wire pair mentioned above.
-
What size puller will I need to remove the flywheel?
You will need an M27x1.0 reverse thread flywheel puller. We recommend getting one from Amazon for around $10. It pulls from the center of the flywheel, preventing warping. Do not use a 3-jaw puller, as this can damage the flywheel.
-
What is the tightening torque value for the flywheel nut?
The correct torque value is 40 ft-lbs.
5. Important Guidelines and Safety Information
-
Operating Voltage and Maintaining a Safe Margin:
Always ensure your system is running at the specified 13.0V charging voltage. Although the system has a buffer to charge the battery under full load, this should be seen as a safety margin rather than a feature for constant use. Prolonged operation at or near full load may lead to overheating and reduced system life. -
Monitoring and Derating:
It’s essential to understand that running the system at its full 160W capacity consistently can strain the components. We recommend that users derate by accounting for accessories, ambient temperature, and usage patterns. This helps ensure reliable long-term performance and avoids heat-related issues. -
Relay Use for Safety:
When adding accessories such as LED lights, DC-converted headlights, or other high-load components, always use relays to manage the electrical load. This prevents potential overloading of switches and minimizes the risk of damage to the electrical system. -
System Testing and Maintenance:
After installation, always test the system under various load conditions to ensure stable operation. Regularly inspect wiring connections, the regulator, and the battery to ensure there is no excessive heat buildup. This is particularly important if you’re operating in high-temperature environments or under heavy accessory loads.
Troubleshooting Tips
-
Battery Not Charging:
Ensure that all connections are secure and that the battery is in good condition. If the battery is older or weak, it may not accept the charge effectively. -
Overheating Components:
If the wiring harness or regulator feels excessively hot, reduce the load and check for any wiring issues. This could indicate an overloaded system or improper accessory wiring.
Disclaimer
This product is sold "AS IS" without any warranty, express or implied. The manufacturer assumes no liability for damages, including but not limited to personal injury, equipment damage, or property loss arising from improper use, installation, or modification of this product. Any statements or guidance provided by the manufacturer or seller should not be construed as expert advice. Use at your own risk.