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Help !!!!!! 200exc 2004 keeps blowing bulbs

9K views 16 replies 5 participants last post by  tatooboy75  
#1 ·
So let's get to the point, I have a ktm exc 200 2004 converted into a supermoto, I was riding my bike in the early hours of the morning with my lights on
and lost all power to lights and horn ect ect, I got home replaced the regulator with my brothers one and it was fine apart from the rear light then kept blowing, so I took a trip to the local ktm dealer and bought, a hand full of bulbs, a brand new regulator, and new harness for the rear light, so I have got home fitted all this and it still blows bulbs :/ have checked the voltage at tickover is around 3-4volts and when reved it's about 12v, so I'm very confused with what the problem is so any help will be much appreciated as I don't know where to look next !!!!

Cheers Arun
 
#3 ·
Cheers mate, have just checked that and I'm getting 35 volts through the yellow spade connector on tick over with the regulator plugged in and 65 when revved, does this mean the brand new regulator I have bought and fitted is not working ?? Or is something causing them to fail !!
 
#4 ·
Regulator is not working. Might be a broken wire.

Measure voltage on yellow wire into regulator and voltage on brown wire at regulator. Yellow should read same as other yellow, if not - the yellow has bad connection or broken.

Brown should be 0V, if not there is a broken brown or bad connection.

Was the regulator connector like new inside? It its dirty, chop the connector off and connect the wires direct.
 
#5 ·
Have now connected all the wires via new spade end connectors because the plug was all grotty and dirty, getting a readout of the yellow with red strip in, of 8volts at tick over when revved 14volts, the White is 0.80 volts, and the other one with two yellows into one is 12volts tick over and still 65volts when revved the earth is reading 0v at all times

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#9 ·
cheers kevtech just stripped the earth cable near the regulator and ran a separate cable and bolted that to the frame checked voltage at headlight and still about 14/15 idle and edging towards 60 with a rev. could it be something to do with the stator or is there a way to test the regulator? cheers
 
#14 ·
Got it - After hours stripping entire loom and testing all the connections I finally noticed a broken connection on the stator coil looks like the solder had just vibrated off or something soldered it up and hey presto all lights working fine popped sown to halfords and replaced my rear leds and all running fine now. Anyone interested in a almost new reg/rec?
 
#15 ·
Hi There, I have the very same issue with my brothers 300 EXC-E, measuring 60V AC at the output of the rec/reg, which we have just replaced. Cannot find any other obvious signs of issue, will check stator when time allows. Did you have to remove any coatings/coverings to access the damage mentioned?
Thanks for your help in advance.
Am I also correct in thinking I have brown=Earth, Yell and Red = +12V from battery, white=AC in from stator and the yellow is regulated output feeding lights etc...
I can't believe that this is the reg/rec faulty again.
 
#17 · (Edited)
Problem solved on my brothers bike:D. stripped stator out of casing and had a really good poke about, could not get a resistance reading from white wire. found the copper wire had snapped off right at the solder joint, invisible until I moved the red/black one from on top AND pressed the wire with a screwdriver. Had to scrape some of the laquer off of the wire to tin and soldered a second piece of wire along side to prevent further snappage.
Resistances of stator wiring should be as follows:
Red to green (pick up coil) approx 100 Ohms, a magnet or screwdriver passed over ot should vary it a little
Red/white to Black/white (Coil going to CDI) reading 14.5 Ohms
Yellow to earth on stator read very low 0.6 Ohm and once repaired, white measured the same. white to yellow read around 0.8 Ohms when repaired.
I have photos to support but it seems I can only upload from a URL, let me know if there is another way.:scooter:
Hope this helps, quite an easy fix in the end
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