TheBackShed.com

Forum Index : Electronics : KTM Dirt Bike Wiring Help!

Author

Message

Mulver
Senior Member

Joined: 27/02/2017
Location: Australia
Posts: 160

Posted: 11:21am 29 Jun 2019

Copy link to clipboard

Print this post

Hey All,

Its no 8 kw inverter but I am playing with AC and DC

I need a little help from the experts! I have a 2005 KTM 300 EXC that i bought a year or so ago. None of the lights / trip meter worked but she runs just fine. So I have pulled her down for a rebuild and while I'm at it I decided to fix the electrics...

Well its a dogs breakfast and somebody has been splicing away. From what I can gather at the stator/magneto is off of a "EXC-US 200-250" so it has 4 wires for the CDI and 1 for the AC lights like below.

But the majority of the wiring is like the below "EXC 125-300" minus the White wire coming out of the Stator/magneto.

Can anyone confirm that i could ground the white wire out of the Reg/Rec. to achieve the desired result? As drawn in pic below.

Any help would be greatly appreciated!!

Ralph2k6

Senior Member

Joined: 24/09/2017
Location: Australia
Posts: 129

Posted: 12:35pm 29 Jun 2019

Copy link to clipboard

Print this post

Only had a bit of a glimpse, but for trial and error you could ground the wire with a fuse link, so if it is not correct then that shall blow, right?

Ralph

radar

Newbie

Joined: 09/06/2019
Location: Australia
Posts: 16

Posted: 04:47pm 30 Jun 2019

Copy link to clipboard

Print this post

hi Mulver,
Your beasty can have 1 of 3 types of Ignition/Mag/Generator
It depended on the dress of it at ordering.

Part No 54839004000 2K-1
Part No 54839104000 2K-2
Part No 54839204000 2K-3

What you show in first picture is 2K-2 Type , If looking for
the correct type to match the 4 Wire Reg/Rec you want a 2K-3
May-be try as Ralph suggested Adding about 2 Ω resistor
and a fairly small quick blow fuse.
Or possibly the wire has broken off.
.

Edited by radar 2019-07-02

Mulver
Senior Member

Joined: 27/02/2017
Location: Australia
Posts: 160

Posted: 12:04pm 06 Jul 2019

Copy link to clipboard

Print this post

Thanks Radar! This was really helpful. I can confirm my stator is the 2k2 version with one side of the charge coil going to ground.
So I will test running the white wire on the rectifier/regulator also connected to ground.

radar

Newbie

Joined: 09/06/2019
Location: Australia
Posts: 16

Posted: 02:21pm 08 Jul 2019

Copy link to clipboard

Print this post

Mulver I will search the shed on the weekend , I think i might have a 2k-3 not sure it is from a 300EXC But that wont matter , Manly so as to get a clear picture of how it is wired , From memory i think the 2k-3 has two extra coils compared to the 2k-2 .
2k-1 has same amount of iron post as 2k-2 but not all of them are wound .

300EXC came with Dressing .

Headlight + Tail,
Or
Headlight + Tail + Blinkers
Or
Headlight + Tail + Blinkers + Battery

Aus Country requirements Must have park lights without Motor running .
( Headlight + Tail + Blinkers + Battery )

Mulver
Senior Member

Joined: 27/02/2017
Location: Australia
Posts: 160

Posted: 12:01pm 09 Jul 2019

Copy link to clipboard

Print this post

Thanks Radar. I feel my bike is a bit of a cobble together after a crash possibly. Originally it would have been Headlight + Tail + Blinkers
absolutely no battery.

Wiring lines up perfectly to the second picture in the original post. Minus the white wire.

So i took some measurements and this is what i got

red+green = 100 Ohms
black/red+red/white = 12.5 Ohms
Yellow Ground = 0.6 Ohms

I think the white wire exists and its been torn out, other wise black/red+red/white should have been = 24 Ohms

I will pull the fly wheel off and have a look.

Do you have any suggested tools to remove the flywheel as the clearance between the flywheel and engine case is limited, what i have does not fit in the small gap?

Cheers Shane

radar

Newbie

Joined: 09/06/2019
Location: Australia
Posts: 16

Posted: 02:55pm 09 Jul 2019

Copy link to clipboard

Print this post

Mulver ,

Removal tool Do a google for

( Ballards M27 x 1.0 L.H (C) Flywheel Puller )

There on evilbay around $20 or so .
And of course all good online stores

It will make it #iss easy to remove .
It is 27MM x 1.0 LEFT HAND THREAD , So you probably wont have any think in the
tool box to Hack a tool together , Yes removing the flywheel is the best
thing to do as there will be no guessing as which stator is there .

2019-07-10_005105_EXC-250-300-2005.pdf

Pdf is 5 page breakdown of the full schematic with a little color splashed in,
It may help or not .
Radar.Edited by radar 2019-07-11

Mulver
Senior Member

Joined: 27/02/2017
Location: Australia
Posts: 160

Posted: 05:47am 14 Jul 2019

Copy link to clipboard

Print this post

Tool acquired, flywheel off, even more confused !

No white wire!

Is the green arrow pointing to the CDI coil? (red and Black Wire)
Yellow arrow is ground.
Pink arrow is yellow wire and connected to one side of the coils
Blue arrow does not appear to be connected to anything.

Edited by Mulver 2019-07-15

radar

Newbie

Joined: 09/06/2019
Location: Australia
Posts: 16

Posted: 02:56pm 15 Jul 2019

Copy link to clipboard

Print this post

That stator is a 2k3 140 Watt .
Mnn Seems to be wired different than i have seen , Not saying it is Wrong though .
Here are some pictures of a few 2k3 i have .
Notice the wiring difference looks like one of your poles
is not soldered to anything , on mine .
yellow to ground through coil
White to ground through coil .
Black/Red through coil to Red/White

Next Picture is a 2K3 from 1998 Note the Wiring Tails
And compare to next photo

Next Picture is a 2k3 from 2008 Note the Wiring Tails
What type of tails do you have .

Next Picture is from a stator 300EXC that was up for grabs on
GumTree last week . Note The wiring tails . Pretty poor picture
but if blown up you can see 4 wires on the stator ,
The Pulser wires RED & Green do not go to the stator .
Normaly 4 wires on a 2K3 stator for + Two for the Pulser?

Can you snap a few shots of your harness , Mainly the voltage reg
and its tails ,

The intermediate harness Tails also,
It is the one that plugs in to cdi .

Mulver
Senior Member

Joined: 27/02/2017
Location: Australia
Posts: 160

Posted: 11:32pm 15 Jul 2019

Copy link to clipboard

Print this post

Not currently at home. But I can confirm this is the loom I have but without the white wire.
4 pin plug that goes to cdi. And one yellow wire.

What is interesting is if you look at the windings of your photos compared to mine, mine appears to have all 7 fully wound packed to the brim.
Edited by Mulver 2019-07-17

radar

Newbie

Joined: 09/06/2019
Location: Australia
Posts: 16

Posted: 10:21am 17 Jul 2019

Copy link to clipboard

Print this post

Mulver said What is interesting is if you look at the windings of your photos compared to mine, mine appears to have all 7 fully wound packed to the brim.

Yes It does , Have a look at this Link it might fill in some of the missing
story of your beast .

As you said

Quote Well its a dogs breakfast and somebody has been splicing away

Here is the 2019-07-17_183253_STATIC_GENERATOR_VALUES_300EXC.pdf It may help diagnose the alt .

Print this page

To reply to this topic, you need to log in.