Lighting not working

W

Wilksiee

New member
basicly my 2004 ec250 when i bought it, the front and rear light worked

but i went to start the bike one day and the light came on and was flickering loads, i thought it was because the bike was cold and then it worked normaly after riding it.

but i think that was the start of a problem because now after riding to work and back...no lights come on at all.

i dont think its the bulb as rear light dosn't work either
ive checked for earthing but can't see anything.
ive got alot of free wires as i dont have a speedo, but everything seems to be connected... i can upload pictures if its easier butt any ideas anyone?

i realise it could be a massive list of problems, but i could do with a point in the right direction as im crap when it comes to sparky!
 
Wilksiee said:
basicly my 2004 ec250 when i bought it, the front and rear light worked

but i went to start the bike one day and the light came on and was flickering loads, i thought it was because the bike was cold and then it worked normaly after riding it.

but i think that was the start of a problem because now after riding to work and back...no lights come on at all.

i dont think its the bulb as rear light dosn't work either
ive checked for earthing but can't see anything.
ive got alot of free wires as i dont have a speedo, but everything seems to be connected... i can upload pictures if its easier butt any ideas anyone?

i realise it could be a massive list of problems, but i could do with a point in the right direction as im crap when it comes to sparky!
Click to expand...
I am assuming your stator puts out an AC signal. Since you can ride it, we know the ignition works. Start at the regulator/rectifier. Check for power going in, and power going out(and @ what voltage). If that checks out, then you have the task of running down each wire, and checking every connection. You may have to remove all of the bodywork & fuel cell. It's a tedious pain, but not difficult. Good luck, let us know what you find.
 
brillant thanks!...sorry to sound so retarded but where do you think i would find the regulator/rectifier.

and want can i used to messure what goes and and what goes out, will the bike have to be running whilst trying to get a reading?

Thanks your help is appreciated.
 
Your regulator might be in frame bolted with ignition coil (it should be, that small black box if original). You should test voltage for example from your front coupling. Maybe someone here can tell exact voltages that there should be I think it should be under 15v when rpm's are about 6000. It's AC voltage if you don't have battery in your bike...
 
Last edited:
yes theres a black box next to ignition coil...
test voltage from front coupling?

im gunna have a mess round see what i can do :L
 
to test voltage, you'll need a basic AC/DC multimeter. read the instuctions that come with the unit(it'll save a lot of time). they very inexpensive, and will save hours of frustration. find the section of wiring that runs from the stator to the regulator(mine is in the airbox...no battery). next, find the connection from the regulator out to the accessories i.e. lights, etc. unplug the harness from the reg. and check voltage coming from said regulator. work your way out toward the accessories, checking for voltage at each connection. look for telltale marks on the wires themselves, like sharp bends, or creases in the wire indicating a possible break. also look for discoloration in the wire insulation coloring. that would indicate a short, and the wire getting hot. electrical issues are usually not that tough to figure out, but they do require patience, and attention to small details.
 
You might also pay attention to the wires where they attach to the pins inside the plastic junctions/connectors. My lights quit working over time and when I finally decided to check it out I started by checking the connections. Gentle tugging on the wires at the connectors and before I knew it I had a handful of seperated wires. They were never crimped well and were all coming loose from the pins. But they all appeared fine visually.
 
replaced the left hand switch gear to lights as mine was cracked and not working propperly
and also replaced the regulator/rec with a new one.

yet it still dosn't work!! where would be the next place to check?
ive had a good look through all the wires and can't see any breaks.

THe kill switch works!!:o just nothing propperly electrical, eg lights, horn brakes and things.
 
Wilksiee said:
replaced the left hand switch gear to lights as mine was cracked and not working propperly
and also replaced the regulator/rec with a new one.

yet it still dosn't work!! where would be the next place to check?
ive had a good look through all the wires and can't see any breaks.

THe kill switch works!!:o just nothing propperly electrical, eg lights, horn brakes and things.
Click to expand...
Checking in. Have you ironed out the electrical issues?
 
no still havn't solved the issue!

im going round a friends tomorrow and he's going to wire up his stator to my loom as he has the same bike as me.

if then the lighting works, then it will mean i need a new stator.


not sure what else it can be
 
Very Good. Then you've already accomplished a lot. Most of the dirt riders I'm around, are too scared to troubleshoot electrical problems. Hopefully, you'll have it sorted out, very soon.
 
just to let you know, today i went around a friends house and he disconnected my stator and connected a car battery to the yellow wire.

and my lights came on! horn worked! ideal!!

so its my stator thats gone! so im going to order a new one the weekend.
i'll let you know what happens.

thanks for all your help:)
 
i bought a stator off a ktm 200, fits straight in..wires and all...i fitted that earlier
and my lights are working again :)

my old stator, all the coils were black and crisp so ive got an earthing problem somewhere which im looking to fix tonight

so sorted :D thanks all:)
 
Hmm sounds exactly like the problem i have/had on my 03 ec 250..

Might try me a new stator.. :-D

Cheers,
Nik
 
yeah atleast take your flywheel off and have a look at the stator.

if its gone, all the copper coils will be burnt out like mine was
then you know for sure, new stator.
 
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