All lights blinking EC300 2007

[stian]

All lights blinking EC300 2007 (with pics)

Hi. Just got my new headlight, taillight. Havent had it on before since I bought the bike.

Starts up, new voltage regulator, no battery. Taillight blinks fast, frontlight blinks fast. Voltageregulator earth together with CDI earth to the frame.

Think thats it. Anyone got a suggestion?

 

[Neil E.]

Haven't heard of this before, but it sounds like you are seeing AC voltage sine waves. Does it blink faster (change in frequency) when you increase revs? This would be more evident with LED lights compared to incandescent lights. Is it a stock voltage regulator or an aftermarket full wave regulator/rectifier?

 

[gasgasman]

+1

Make sure the voltage regulator is for A/C voltage.

 

[stian]

Haven't heard of this before, but it sounds like you are seeing AC voltage sine waves. Does it blink faster (change in frequency) when you increase revs? This would be more evident with LED lights compared to incandescent lights. Is it a stock voltage regulator or an aftermarket full wave regulator/rectifier?

Its stock GasGas, Bought at GasGas store. its a 12V AC (thats what it says on it)
Its flickering in any RPM. no more or less at any.


Both the taillight,headlight and also, the light switch that should light green when headlight is on is blinking. Trailtech Vapor also flickering very.

Called a buddy of mine, he told me to check the power that comes from the stator/engine, before the voltage reg. Guessing it should give 14,3v or something? Ive got a multimeter, but dont know how to use it. Its got VAC,ADC,VDC, ohm and "bat."


Its kinda funny, because ive got so little knowledge about electrics.

Questions;
1) White wire, what is it for?
2) Yellow wire, what is it for?
3) Anyone see anything that should go where?

 

[Neil E.]

Your signature says 2007 EC300 so you likely have the 2K3 stator. Your bike would typically not have a battery, so the white wire from the stator is unused (and should be left disconnected). The yellow wire is AC voltage output from the stator. It connects to all your lighting components through various switches. It also connects to the voltage regulator to limit the peak voltage.

Look around the wiring and make sure only the green/yellow wires are grounded (chassis/engine ground). Check the quality of the ground connections and be sure the ground points are bare metal. One test you could try is to unhook the voltage regulator and see what happens. Warm the bike up first and ONLY have it idling when you unhook it. Do the lights stop flashing? Don't rev the engine or you will burn out bulbs.

 

[stian]

Your signature says 2007 EC300 so you likely have the 2K3 stator. Your bike would typically not have a battery, so the white wire from the stator is unused (and should be left disconnected). The yellow wire is AC voltage output from the stator. It connects to all your lighting components through various switches. It also connects to the voltage regulator to limit the peak voltage.

Look around the wiring and make sure only the green/yellow wires are grounded (chassis/engine ground). Check the quality of the ground connections and be sure the ground points are bare metal. One test you could try is to unhook the voltage regulator and see what happens. Warm the bike up first and ONLY have it idling when you unhook it. Do the lights stop flashing? Don't rev the engine or you will burn out bulbs.

The engine should have a ground from the case, and the other ground is the coil.

I just replaced my old voltage regulator with a new one. It sits in the same bolts as the coil, and has the same ground spot. It also connects with a yellow wire.

As stated, there are two yellow wires. I am going complete insane soon... haha!

 

[Neil E.]

I haven't got much to add here, but the basic bike wiring diagram (non-estart) shows that the regulator black wire is grounded. So make sure the black wire has a nice clean connection to the frame.

To recap, your yellow stator wire carries varying ac voltage depending on RPM. The regulator simply clips the peak voltage when it rises above ~13VAC and it does this via the black wire to ground.

Do not assume that grounding takes place through the regulator case. It is just a mounting point. I can't suggest anything other than a better way to test things. I would unhook your stator yellow wire and connect it ONLY to the yellow wire on your regulator AND a 12V bulb. Other side of the bulb grounded. Start the bike and see what happens. If the bulb works without flashing, then the problem is somewhere else in the wiring.

Add in other yellow wires (like the one to the headlight switch) and check each time you add one. Without much electrical experience this is hard to do. You basically have to open the harness and unhook all the yellow wires from their junction point. Try adding them to your circuit one at a time.

If this is too difficult, you need to take it to a dealer and have it checked out further. That's all I can suggest.

 

[stian]

I would unhook your stator yellow wire and connect it ONLY to the yellow wire on your regulator AND a 12V bulb. Other side of the bulb grounded. Start the bike and see what happens. If the bulb works without flashing, then the problem is somewhere else in the wiring.

Ok. Is there any difference between Current electric regulator, and Voltage regulator?
Cause this is the one I got http://www.motocrosscenter.com/ecommerce/product_info.php?cPath=667_675&products_id=60656

Also I have this laying around http://trialstribulations.net/index.php?main_page=product_info&cPath=31&products_id=699

 

[Neil E.]

No difference, just how things are translated (or referred to). That is the correct part for what you want to do (AC lighting hookup).

 

[stian]

No difference, just how things are translated (or referred to). That is the correct part for what you want to do (AC lighting hookup).

You seem to be the electro-guy in here, and im qouting you from another thread:


"Ground = yellow/green wire at ALL places where it connects. You could have a poor ground at various locations. Easy way to check is to jumper from the yellow/green wire at your headlight to any bare chassis point. If your headlight is bright, you know it's a ground issue."

Since im all green in this, care to explain? Now the yellow/green wire is at the front, at the back. The only ground wire ive got, is the coil to the frame, and the Voltage Regulator to the frame.

No other ground wire. Only 2 places.

 

[Neil E.]

Easiest explanation is to think of a battery hookup like on a car. Red=positive terminal, feeds all power out to the vehicle. Black=negative, ground wire for all components. Connected to vehicle frame etc.

Your bike: Yellow=stator output, supplies all power to the bike (engine running). Green/yellow=ground wire to all components. Connected to frame and engine. If you use a voltmeter set to ohms you should get continuity from any green/yellow wire to ground. The ground is common to the frame and engine. Your ohms reading would be very low, less than 1 ohm, indicating a circuit. A high reading (megohms or infinity) indicates no connection.

I can't say for sure about your bike, but it should have a ring terminal with a yellow/green wire bolted to one of the coil mounts, or somewhere else with bare metal on the frame. Maybe someone used a black wire in place of the yellow/green. IF the yellow/green is not connected to ground, maybe that's why your lights are flashing. There could be arcing going on.

Please cut your harness cover open and follow the yellow/green wires and see where they go. Or push/pull the yellow/green wires back and forth in the cover and find out where they hook up. Somewhere along the way you need to find out where the yellow/green wiring is grounded. You will need to make the ground connection yourself if it's missing. It's the "other side of the circuit", nothing will work properly without it.

So you have a grounded black wire? Follow it around and make sure it connects to a yellow/green wire somewhere. The black wire on your voltage regulator also connects to ground.

 

[stian]

Easiest explanation is to think of a battery hookup like on a car. Red=positive terminal, feeds all power out to the vehicle. Black=negative, ground wire for all components. Connected to vehicle frame etc.

Your bike: Yellow=stator output, supplies all power to the bike (engine running). Green/yellow=ground wire to all components. Connected to frame and engine. If you use a voltmeter set to ohms you should get continuity from any green/yellow wire to ground. The ground is common to the frame and engine. Your ohms reading would be very low, less than 1 ohm, indicating a circuit. A high reading (megohms or infinity) indicates no connection.

I can't say for sure about your bike, but it should have a ring terminal with a yellow/green wire bolted to one of the coil mounts, or somewhere else with bare metal on the frame. Maybe someone used a black wire in place of the yellow/green. IF the yellow/green is not connected to ground, maybe that's why your lights are flashing. There could be arcing going on.

Please cut your harness cover open and follow the yellow/green wires and see where they go. Or push/pull the yellow/green wires back and forth in the cover and find out where they hook up. Somewhere along the way you need to find out where the yellow/green wiring is grounded. You will need to make the ground connection yourself if it's missing. It's the "other side of the circuit", nothing will work properly without it.

So you have a grounded black wire? Follow it around and make sure it connects to a yellow/green wire somewhere. The black wire on your voltage regulator also connects to ground.

Thanks mate.

Since the only 2 ground wires are 1 black With the coil and 1 black With the volt regulator, im guessing arcing is going on.

Going to cut Thanks again!

 

[stian]

Stator output measured at yellow stator wire and frame earth shows between 2,5-3v.

im guessing my stators quite dead.. whats the cheapest alternativ.?

 

[Neil E.]

Measuring voltage with your meter on the AC scale, regulator disconnected? At what RPM?

Stator wires only (not running, temperature must be 20*C or 68*F), what ohms readings do you get yellow to ground and then yellow to white? The GG manual says yellow to ground .67 ohms +/- 20%, yellow to white .16 ohms +/- 20%

Also check the stator solder joints to make sure they look good. You need a flywheel puller M27 left hand thread. Did you for sure find that the yellow/green wires are grounded?

Trailtech has a stator kit for KTM that might fit GG by changing the connectors. http://www.trailtech.net/stators-flywheels/sr-8312
Puller http://www.trailtech.net/stators-flywheels/accessories/6300-p01

 

[stian]

Measuring voltage with your meter on the AC scale, regulator disconnected? At what RPM?

Stator wires only (not running, temperature must be 20*C or 68*F), what ohms readings do you get yellow to ground and then yellow to white? The GG manual says yellow to ground .67 ohms +/- 20%, yellow to white .16 ohms +/- 20%

Also check the stator solder joints to make sure they look good. You need a flywheel puller M27 left hand thread. Did you for sure find that the yellow/green wires are grounded?

Trailtech has a stator kit for KTM that might fit GG by changing the connectors. http://www.trailtech.net/stators-flywheels/sr-8312
Puller http://www.trailtech.net/stators-flywheels/accessories/6300-p01

Measuring voltage with your meter on the AC scale, regulator disconnected? At what RPM?

- AC, regulator both disconnected and connected, in all RPMs. Between 2-3volts.

Stator wires only (not running, temperature must be 20*C or 68*F), what ohms readings do you get yellow to ground and then yellow to white? The GG manual says yellow to ground .67 ohms +/- 20%, yellow to white .16 ohms +/- 20%
-Did not check. Seen the volts be 2-3, it was quite clear it was the stator.


Also check the stator solder joints to make sure they look good. You need a flywheel puller M27 left hand thread. Did you for sure find that the yellow/green wires are grounded?


- Ive got the puller already, but its at another workshop. Im checking the solders, and ive checked the hole loom for errors. Also found a local workshop who possibly can re-do the stator

 

[Neil E.]

The only thing that seems strange is that you have lights flashing when the stator is delivering 3 VAC. If we take the flashes as AC peak voltages, I don't see how 3 volts can make anything light up. Three volts would normally only result in a tiny glow on a light bulb filament. Now if you had described the events as "lights barely flickering", maybe you are right.

There still may be something else going on. You didn't mention what you found on the yellow/green wires. Did they actually connect to your black ground wire?

 

[stian]

The only thing that seems strange is that you have lights flashing when the stator is delivering 3 VAC. If we take the flashes as AC peak voltages, I don't see how 3 volts can make anything light up. Three volts would normally only result in a tiny glow on a light bulb filament. Now if you had described the events as "lights barely flickering", maybe you are right.

There still may be something else going on. You didn't mention what you found on the yellow/green wires. Did they actually connect to your black ground wire?

3VAC, taillight and front parklight, and light-chooser are blinking. Havent wired up main headlight for the last days, but its a good flickering there too. The flickering are good, not a tiny glow.

The black ground wires is the one at the coil, and one at the volt regulator. There isnt any other ground wire. There are no yellow/green connecting to blacks. There is only the stator wire, who is all yellow, and connects to the coil.

 

[Neil E.]

This may sound silly, but how do you expect any of your lights to work if they aren't grounded?

Let's take for example your headlight bulb wires: blue (high), white (low), and green/yellow (ground). Yellow comes to your switch and out on blue or white. If the green/yellow is NOT connected to ground, there is no circuit to make the headlight work!

There is only the stator wire, who is all yellow, and connects to the coil.

I don't understand this, unless you mean the yellow connects to the stator winding. It definitely should not connect to the ignition coil. If it was connected to the ignition coil mount, that is frame ground and you would be shorting out the stator ouput. In that situation, if it's a poor quality ground, you might see 3 volts at your meter.

Get a copy of the GG wiring diagram and study it to get an idea of what the wiring actually does.

 

[stian]

This may sound silly, but how do you expect any of your lights to work if they aren't grounded?

Let's take for example your headlight bulb wires: blue (high), white (low), and green/yellow (ground). Yellow comes to your switch and out on blue or white. If the green/yellow is NOT connected to ground, there is no circuit to make the headlight work!


I don't understand this, unless you mean the yellow connects to the stator winding. It definitely should not connect to the ignition coil. If it was connected to the ignition coil mount, that is frame ground and you would be shorting out the stator ouput. In that situation, if it's a poor quality ground, you might see 3 volts at your meter.

Get a copy of the GG wiring diagram and study it to get an idea of what the wiring actually does.

The wiring Connected to the coil and voltage regulator is correct. Its just me that cant Write it in a way others can understand.

I am going to check ohms and every wire and wiring for faults, but the bike starts good, and are driving Perfect, s? the missing ground wire(blue) is not going to affect the system in this way.
For now, ive taken som Calls, and stators the big crapper.

Found this; http://www.ebay.com/itm/Stator-GAS-...&fits=Model:EC300&hash=item4166fc9f11&vxp=mtr

Guess it is crap or working alright?

It seems to me that I am missing the Blue ground wire. Also, previous owner did ride the bike without a voltage regulator.

 

[Neil E.]

The missing voltage regulator would not matter if no lights were connected. It looks like the older bikes used different wire colours than the newer bikes. The yellow/green wire that I refer to as ground, looks to be the blue wire on your bike. With that blue wire disconnected, your light bulbs aren't in the circuit. What happens when you hookup that ground? The flashing should at least stop.

Actual stator output is a different story. It is possible that your stator is bad. As long as the bottom end of the winding is grounded, you should be able to measure reasonable voltage ouput when testing from the yellow wire to ground (bike running).

Keep at it, it's not rocket science.