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  1. Hi everyone and merry chrimbo to all. Ive pretty much finished my resto project and everything’s great apart from the dim lights. I bought the bike with the problem, and thought it would be an easy fix. Nothing seems to fix the fault. So far, I’ve replaced the whole wiring harness, the rear light and wires, brake light switch and wires, front light holder and wires, speedo cable and wires. All 6v bulbs and I even had the light coils checked and replaced. So everything has been done apart from the handlebar switchgear. I had the frame powdercoated, but sanded the main earth point for the harnsess, so it’s a good earth. Even, ground two points of the five engine mounting points away hoping that might help. All the electrics work like they should including the pass light, just dim lights. Has anyone had this problem? Does the engine need to be grounded at every point? I thought if the engine had one good ground that would be enough. Really at a loss with this, and if I can’t sort I have to admit defeat and had it over to an auto electrician ?
  2. Hi, I'm hoping someone can help? Have just put together a 1983 PE 175 and bike runs fine, lights are slow to come on and dim. Brake light blows when applied and horn pretty asthmatic too. If I disconnect one either light and the other goes nice bright. Other than I nailed it!! Have checked wiring against a diagram I found on the net and all the wires are where they should be. Checked the connectors on the light related wires and cleaned. Also ground the powder coating back on the earth point. Really haven't got a clue why it the way it is. Any help will be much appreciated, as I spend most nights doing the same thing over and over again which is a little underwhelming. Cheers waz
  3. Hi All, I searched but could not see anything that described my issue. Not much on the WWW either. Background is that I’m bring a second hand 2004 KTM EXC 525 back to life. All is going well. Main issue I have had was with the starter motor but this has been resolved by a good valve adjustment and a good strong battery. The bike does start on the E Starter. So... Recently I started the bike on the E Start and I went for the first longish test ride and it went fine. After about an hour on the road I pulled up at a scenic place and stopped the bike. I took a few photos and hopped back on the bike after about 5 mins. The bike started with E Start no problem. A few minutes later I went off road to have a play and practice (I’m a bit new to big Dirt Bikes). While practising I stalled the bike. I pulled the clutch in and pressed E Start and nothing. I think I heard a click but not sure. I kicked the bike over fine and continued practice for about 15mins. I arrived home about an hour later and pulled into the garage and hopped off. I put the bike in neutral and thought “I’ll just try that E Start again”. This time I did hear a click but it did not turnover. I left it and went and made dinner. A couple of hours later I went to shut the garage and thought again “I’ll just try that E Start”. It started no problem at all. WTF?. The next day I had to run some errands. The bike started off the E Start no problem in the morning. I rode for about 15min then came home. Somehow I stalled the bike in drive way (which surprised me). I pulled the clutch in and pressed E Start and nothing. This time I had the presence of mind to check other electrics. I turned the blinkers on (which don’t require motor running) and they did not work. It was dead electrically. Put the bike in neutral and tried E Start still nothing. I kicked the bike over in one kick and motored up the driveway and turned it off and hopped off. I put it in neutral and pressed E Start and it started fine. What gives? I have done some reading and read that a Bad Earth connection could be the issue or a short somewhere. I have a multi meter so I did some testing. The Battery is good. It’s new, it’s lithium and it's reading 14.5V across the terminals. The Positive to Earth connection is 14.5V. The Positive to Frame near Earth is 14.5V. Positive to Lower Frame, Started Motor and Engine Case is 14.5V. I don’t think this is a Battery or Earth Issue (but I could be wrong). These are my thoughts and questions; What seems to be common is stalling the bike. Is there some sort of electrical discharge time needed after a Stall? Is the stalling itself part of this problem? When stalled is that jolt possibly making a short somewhere?. If there was a part/path that might need replacing what would it be? (I just had this thought. Maybe had the front/back brake actuated which would be triggering the brake light electrics. Perhaps that is an issue? I’ll test this and report back. Brake lights and Headlights are running gear so only work when motor is running though. This is an AC/DC thing ? ? Also, On speaking to my local KTM shop about this I have been advised to change the On/Off/Start module to Start only and use the Kill switch on the other side. Apparently the On/Off Button is an addon for those countries that require it and is not an OEM KTM part and has known issues. They did not have the part in stock but they will have it in about a week. It’s not expensive and figure it’s a logical trouble shooting step. Sorry, more questions than answers. Thanks in Advance TT
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