1985 XR 600 electrical issues

[mr-Jrod]

So basically....

The other day my lights and horn stop working, got home and wiggle some wiring and it all came on and worked fine for about 2 minutes. Now I can't get them to work.

The bike still runs and measuing across the stator at idle its between 35-38v

Measuing across the regulator I get 0v? (well like 0.1 to be precise) I've studied the wiring diagram and the power from the stator goes directly to the CDI, this then feeds back to the Reg I guess? Is it likely to be a faulty CDI if no power is going to the reg or a wiring issue? As I say the bike still runs fine...

Also I was considering it might just be a bad ground but where is the ground on this bike?!

[Greasser]

Is it a XR or a XL?? I've never heard of a XR that had a horn.

[Horri]

In countries other than the US these bikes came into the country as road legal..ie they needed horns, indicators, lights to be able to pass the government standards for road use and registration for that purpose.. Unfortunately the stock Stators kind of gutless but adequate when new. My 86 came stock with all that stuff. Seems obvious to me that if you wobbled the wires at a certain point and things started working again then the problem is in that area..Generally behind the Headlights that area, as all the wiring meets and connects into things there..or maybe the Stator side of the wiring which runs the lighting is faulty...Check it. The ground connection to the frames normally around the ignition coil area..

Edited March 28, 2010 by Horri

[mr-Jrod]

Sorted.

As soon as I was told it had 2 coils in the stator I realised that just because the engine was running it didnt mean power was getting to the light system.

I traced the wire down to the stator and alas, it has shorted out on the frame.