No Volts

Nope, haven't had that problem..

...but seems you've checked about everything but the stator itself. Take off the flywheel and check the connections to it. The lighting coil isn't nearly as protected as the ignition coil...it's just varnished transformer wire with no covering on it at all.

Checking it with an ohmmeter isn't going to tell you a whole lot, but at least would tell you if there's a high resistance problem somewhere..like on the stator/case connection.

You could take your voltage regulator out of the circuit to see if it's the problem. Take your bulbs out too when you check it. Don't know how high a voltage you get with no VR..but probably high enough to blow up your bulbs.

Check to see if there are any short problems on the tail light side of things. I don't read in your post that you checked for shorts in general. If you take your flywheel off so you can disconnect the stator, with the bulbs out you could check that out. With the stator connected (or the bulbs in) you get a 'short' most everywhere with a VOM.

Good luck.

re: flywheel pulling

Get the tool. Costs all of $10-12 at your local bike shop.

Don't know of any other way to get it off.

But..if you don't have one, haven't used one (just want to cover all the bases...not to be simple-minded)..you are aware that the flywheel has left hand threads? The puller is a concentric, oppositely threaded unit..LHT into the flywheel, RHT on the center bolt that applies pressure to the crank end.

If you try to take it off with handtools, you'll need something to hold the flywheel. I've not tried to take it off that way..you won't be holding it by hand..and you don't want to be using any screwdrivers stuck in holes!

I use an impact wrench. DC or air, either one works fine.

Use thread lock when you put it back on. Tighten to spec!! (at least). My riding buddy had his off awhile back to put in a lighting coil. His DC impact was a bit low on charge. It wasn't 1/2 a mile before he'd sheared his woodruff key!! You certainly are going NOwhere when that happens.

Depending on your lighting situation/needs...you might want to think about replacing the lighting coil as long as you're in there. The stock unit won't run any aftermarket dual-headlight system (well..not without replacing the bulbs and disconnecting your taillight). They run around $80, last I looked.

Hope you get it pretty quick. Wiring problems stink!!

..well...imo and all that..........

Get it fixed???....

...yet??

What was it??

I just added a aftermarket UFO headlight to my 92 kdx200. I bought the bike used and it didn't have the headlight. The ufo aftermarket one has a small fuse shaped bulb on top and a huge (car tail light style) bulb in the middle. The big bulb also has some sort of metal reflectors on the sides and bottom. Any way the top bulb works fine when I hook it up but it doesn't put out much light. The large bulb barely glows orange and the tail light goes out when i connect it. What is this a sign of? Can I increase the wattage of the top small bulb or decarease the other one to get the type of light that I need to ride home in the dark.

Unlike the OEM bulb, the UFO bulb probably has two filaments: Hi & Low beam (mine does). Are both of them glowing at the same time? Only one should be in use. Assuming '92s have a 12vdc bulb, get some alligator clip jumpers (Radio Shack) and use a car battery to test out the UFO to satisfy yourself you have it wired up right and it's not the problem.

BRush, thanks for the reply. I took a second look at the wires, and wiring. I didn't have it wired right. I had the wires to both filiments connected, so instead of trying to burn one 35w light I was trying to burn two 35w filiments. With just one it is very, very bright. Thanks for the help.