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Electrical nightmare (short book)

Posted: 05:31 pm Mar 17 2008
by pezvela
OK, it seems I have somewhat of a hybrid KDX250 US/SR and in the process of stripping the frame for paint I came across a hidden disaster of wiring. The previous owner has cut, spliced, twisted, taped with masking tape, switched wire colors, and rewired the stator......resulting in me having NO SPARK now that I am reassembling. If I took a picture, all of you would laugh....I promise, I did. The bike ran before disassembly and I am now trying to figure out what happened.

What I have found is that coming out of the stator I have w/r, w/g, aqua (look like original wiring)and 3 yellow wires (not original)which are tied into the back of the stator. Would one of these yellows serve as the BLACK wire that the diagram shows leading into the CDI? All 3 show slight voltage increases when hand cranking the kick start.

I'm gonna take a picture for every ones enjoyment. I have 3 days staring, changing and trying to figure out what is going on and nobody in this country to bounce ideas off of.

Posted: 05:51 pm Mar 17 2008
by pezvela

Posted: 05:58 pm Mar 17 2008
by radonc73
Wow, my brain hurts just looking at that.

Posted: 07:50 pm Mar 17 2008
by pezvela
I just switched a wire, put the multimeter on it, kicked it over and it shocked me so hard I punched the side of the block. Problem solved......somehow. Pura vida!

Hmmm...

Posted: 10:25 pm Mar 17 2008
by urnuts
That's not factory? WTF?

Posted: 07:10 am Mar 18 2008
by pezvela
Its factory if the plant was in this country.

Posted: 08:03 am Mar 18 2008
by kdxquebec
:twisted:

Posted: 09:20 am Mar 18 2008
by MXOldtimer
Hmmmmmmmmmm, looks like congress had something to do with that wiring.

I think I'd go to e-bay and buy a complete ignition/wiring harness.




.

Posted: 10:09 am Mar 22 2008
by pezvela
Well, got it all back together and fired it up. Motor was running choppy but I was thinking that some trash may have gotten in the jets. Would rev to 1/4 throttle and then break up real bad. Then it died. No spark again. I have power coming from the stator, voltage regulator and if I meter the blue wire from the CDI to the coil and the kill switch I get juice, but if I meter the blue wire to a ground point I get nothing. Doesnt make sense to me. Is it possible to check an ignition coil with a multimeter?

Posted: 11:26 am Mar 22 2008
by AwfulSmokey
>|<>QBB<
MXOldtimer wrote:Hmmmmmmmmmm, looks like congress had something to do with that wiring.

I think I'd go to e-bay and buy a complete ignition/wiring harness.

!!!

Posted: 10:01 am Mar 23 2008
by pezvela
If someone can tell me where to buy an "SR" harness I would be more than happy to go that route. I have searched the interweb with no luck.

Posted: 11:24 am Mar 23 2008
by MXOldtimer
Well, if you can still find the bikes for sale like this one you sure should b able to find parts if you look.
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