97 KDX200 Headlight/Wiring problems

Picked up my new/secondhand 97 kdx200 last night ... I picked it up fairly cheap and, as a result, the girl needs a bit of attention :nod:

The first problem I'm trying to solve is wiring ... the previous to previous owner apparently used it on the farm and obviously didnt want the road gear, but was very destructive about removing it. He has simply cut through the whole loom between the plug that goes into the speedo unit and switch blocks and pulled the whole thing off :bang:

So, what I have here is essentially a bunch of wires poking out from around the steering head that are just bare ends. The switch blocks have also been removed etc. I have the original headlight unit and just want to wire it up as always-on, low beam fine (just to pass the legalities of rec reg over here in australia). I could only get a 12v reading from the two brown wires in the loom, everything else appears dead.

I'm also having trouble getting the rear light to work, the bike to idle, the bike to start and can't bleed the front brake because the m/c screws are rounded off. But other than that it's going great! :laugh:

I'm looking around for a manual at the moment, but I'm a gimboid when it comes to wiring and anything electrical, so any help is appreciated :cool:

I'm slowly working these things out ... yep, my kdx has (had) the wiring for headlight, speedometer, idiot lights (hi-beam/indicators/neutral), indicators and tail light. Not battery, all magneto.

I'll try and hunt out a few people specifically ... otherwise, I'm happy to be thrown any bones ... ie. the likely purpose of the brown wires in the main loom and the red/black wires that seem to be common as well ... whether I should just connect off the yellow wire going into the kill switch, etc etc...

Ok, ended up wiring the headlight to a brown wire and the ground to a red/black which seems to do the job and not try and blow when a few revs are added. Strangely enough when I measured the brown wire with a multi-meter on AC it gave me an erratic reading between 12-20-26 volts, but didn't seem to spike more than that when some revs were added. Red probe on the brown wire, black (-ve) probe grounded on the bottom yoke. When I measure it on a DC setting it gives a fairly consistent 12v. Weird.

Ok, the headlight and tail lights are wired up and light properly, and dont blow under revs. So good there. But now I've had an ignition problem that have ground things to a halt. Despite running last night I've lost spark, after testing with the old plug and the new one. Got the plug grounded on a head bolt and no spark. It was running like crap before which leads me to believe this is just a further manifestation of an existing problem. I thought it might be the coil breaking down so I picked up one at a wreckers today, but no difference.

I measured the voltage into the CDI under a kick by hand (with plug out) and its 9-10v, which should be able to get up to 12v with a decent kick. The wire that appears to be the pule generator coming out of the stator seems to generate ~ 0.5v into the CDI, but I'm not getting anything meaningful when kicking over by hand between the CDI and the coil...!

It would be strange that the CDI just packed in after the bike was running yesterday, albeit rather crappily. I've been looking around for shorts without a great deal of success. I'm thinking I need to pull of the stator cover tonight and check that all is correct in there?

Sorry for the perstering, but any help appreciated, and thanks again for your previous help CC...

I just pulled the magneto cover off and had a quick squiz ... there was a little premix residue in the bottom of the case ... is this supposed to be a sealed unit? It does have a gasket so I'm assuming that's no big deal ... the pulse generator unit (black boxy thing bolted to the case on the bottom lhs) has very little air gap when the raised section of the flywheel comes a whizzing past ...

I'm still waiting for my manual to come (on backorder from kwack) ... anyone have any voltages/resisteance I can check things out for? I'm kind of lost when it comes to electrics (if you haven't noticed) so any step by steps would be most useful....

So can anyone tell me what voltage to expect from the pulse generator going into the CDI? I'm reading about 0.5v which I'm not is enough or not to trigger the CDI which could explain the lack of voltage going out to the coil...