250-500cc Did I Mess Something Up?

I'm working on getting my new-to-me 2009 WR250 ready to go for the season. It's my 1st 2 stroke so I need to get used to all of the nuances.

My big project is getting the lights installed and connected. PO has a KTM headlight on it powered by a 9V battery and a switch. I cut that setup off. He did give me the factory harness, though.

So, thanks to a lot of help from members here, I've been testing and connecting the harness to the bike and lights. Purchased a Polisport tail light combo with regular bulbs and brake switch. I re-wired the KTM headlight.

To test the connections with the bike not running, I connected 2 big 6V flashlight batteries to act as the stator and fed them through the harness. However, when I made the first connection from the batteries, I tied into the wire LEADING to the stator, instead of the wire leading into the harness. I know, bonehead move. There was a small spark when I made the connection. I figured out what I did wrong after a few seconds and disconnected from the stator wire. All went well after that when I tied the batteries into the harness wiring.

So, last night I connected the harness to the stator and went to start the bike for one last test prior to making final connections and zip tying the wiring to the frame. I kicked and got lots of compression but no start. I kicked again and experienced my first 'kick-back'. It did that a few more times, maybe 5 or 6 kicks. After removing the tank and checking connections one more time, I gave it a good kick and it started and ran like normal.

Mind you, I've only ridden the bike up and down my street. However, I've started it several times in the 2 weeks I've owned it and it starts 1st or 2nd kick every time. Solid kicks, but not much effort. It never kicked back at me.

Last night took a lot of effort. I'm wondering if it has anything to do with my connection error of the batteries to the stator. Some more info: it was very cold for 2 or 3 days here in NJ between the last time I started it and last night. Not sure if that has anything to do with the hard starting.

Any advice?

Thanks,
Mike

You probably just had trouble starting it, that happens to me occasionally with no obvious reason. I got a real good kickback (into a sneakered foot, no less) just last week.

Which wires on the stator were you connected to? Your model/year has separate lighting and ignition coils, so even if you did burn up a lighting coil, the ignition shouldn't be effected.

If you did any damage when hooking up the battery, it would be due to putting too much current through the stator windings and frying something. Those wires can be pretty fine, so they might not have the capacity to handle 12V DC with very low resistance (high current). IF anything bad happened, it would be melted insulation (possible short) or a broken wire (wire acting like a fuse), for a possible open. You should be able to ohm out the windings through those same wires and compare them to the book recommendations.

Did the lights and everything work fine when you got it fired up? If so, you're probably fine.

What carb and jetting are you running? Mine seemed to kickback worse when I had the very rich stock jetting in the TMX. After sorting that out it was better (but still does it occasionally).

yes you messed something up. you decided to live in jersey.

JUST PLAYIN BRAH!

Regarding the starting, when I had the Mikuni on my 2011 300 it would kick back pretty violently when the pilot jet was too rich, especially when using the choke when cold. I decreased pilot jet size until it started easier and ran clean in the first quarter turn of the throttle. Even when running well, once warmed up the Mikuni always liked a millimeter of throttle opening to start . But just a little. Few of my friends could start it. I'm a Lectron convert, now.
I also added a headlight switch and leave it off. That seemed to make a big difference when starting with the newer Ducati ignition.

Thanks everybody. Just got back in front of my computer.

Each quarter when I pay my taxes I know I messed up by living in Jersey! I grew up here so I'm used to "it", and all that "it", being in Jersey, entails. At least the pork roll, egg and cheese sandwiches are good here.

Regarding the wiring mistake, I was on the yellow wire from the stator initially, which is meant for lighting I think. When I finally started the bike I didn't actually have the wiring and lighting finalized and installed. I did have the harness connected, though. I touched the lighting wires to the harness wires and things lit up as they were supposed to. I think I'm home free. I'll know for sure when I get home and start it up. I made the final installation and connections for everything last night, just never put the tank on and started it since it was 10:30 at that point and everybody was sleeping.

Regarding the starting, I failed to mention that not only was it cold out but I did use the choke. Maybe that was the problem in combination with the existing jetting.

The PO basically rode about 70% of the time where I'll be riding so I don't plan on changing jetting just yet. I do not know any of the settings, though.

He did change out the stock carb to a Keihin. I've read that's a good thing, maybe not Lectron good from what I've read but better than stock.

PWK is a very good carb, in my opinion. I'd take a look at what jetting you have in there, especially the needle, but you're probably in good shape. Lots of guys love their Lectrons, but I (and most pro racers, apparently) are happy to stick with the PWK.

So it is tough to start tonight, choke and no choke. I've been wearing sneakers the last few times. Will try with boots tomorrow. Maybe its mental.

The lights and speedo worked but not the brake light. It may be getting slightly brighter, and then slowly dims back. I might be seeing things though. It is almost unnoticeable. I'm comparing my wiring to mmichael's and think i match so not sure what the issue is.

My stock 360's lights pulse unless the throttles
Cracked not sure why but its always done it
So im not bothered.
If you rev the bike then do your lights get brighter?