I'm trying to convert my recently purchased 2004 TE250 from its current hare scramble set-up to a dual sport / Enduro set-up. The previous owner gave me the head light and stock wiring harness, so figuring out how to wire it shouldn't be a problem. I figured before I spend the time wiring up the whole bike I'd first check the health of the electrical system. The battery is getting 14.7v DC at idle, so that's not a problem. The headlight on the other hand is only getting 9v AC at idle and less than 5 when I rev it up. I un-bolted the regulator rectifier and checked the yellow and blue connections directly and its getting the same voltage. Is this a symptom of a bad regulator/rectifier? or should I be checking the stator output? Any help would be appreciated.
Sounds like the reg/rectifier to me, might be a good time to switch over to all DC. You can get a new stator and reg/rec from Trailtech for probably less than just the stock regulator.
Good point! Might as well so I can finally have a bike that can run decent headlights! How does one go about converting the entire bike to DC?
Trailtech used to have a kit but I noticed they no longer have them on their website. The stator is the same as many KTM's, you could always get the correct KTM kit and with a little electrical know how its not all that difficult, I did my '05 TE years ago with trailtech parts. The instructions trailtech has on their website (again, for a KTM) can guide you through it. The only difference between the stators for a KTM is the grommet, you would have to cut the connectors off to get the stator wires through your stock grommet. Hope some of that makes sense and helps.
Cool, thanks for the help. Depending on how much the stock regulator is, this may be a good alternative. edit: just called hall's cycle. the stock voltage regulator is only $29! So I guess ill be saving the DC conversion for another day.
