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November 8th, 2017, 06:02 PM   #1
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wiring help, again

Hey guys, Steve here. I just received my ignition components back from Taffy and am trying to install them. I looked in the owner's manual that I got with the bike and found that there are several different wiring diagrams ( enduro, desert, U.S., non-U.S., mx, etc.). The problem is, I have wires that have colors which aren't in ANY of the diagrams! This stuff was disassembled when I got the bike so I am shooting in the dark here. The original owner of the bike was a support rider for KTM for years and he often got bikes before most others could get them therefore I don't know for certain that this is a U.S. bike. But, even if it is a Euro model, the colors for that diagram are different. Very frustrating! The bike, as it sits now, has no lights at all so I just need the basic wiring to get it going. If I want to add lights later, I will cross that bridge when I get there. Three of the wires from the new stator are all yellow and there are three yellow wires coming out of the loom together. My friend, who owns a shop, says they just plug in without any concern for which one goes where. he said it must be a 3 phase alternator (as many other bikes have) and the three yellow wires can be plugged to any of the other three yellow wires.? Thanks for any advice. Regards, Steve
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November 9th, 2017, 02:16 AM   #2
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Hi

I'm just guessing from your post, because I don't know what bike do you have or the stator that you received.

But from you are saying your bike is a pre 2004 bike and you received an electrex stator ?? correct ?

If that is true, then you should pay attention and check if one of the yellow wires has one blue mark, it should. they aren't all the same, one ground and 2 single phases.

If because of any mistake you donīt have any mark, try to find the blue with a multimeter, one of the yellows should be ground, so one of them should be connected with the inner structure of the stator (the place were you fix it to the bike with the screws).

Good luck

ZAGA
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November 9th, 2017, 06:37 AM   #3
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Yes, one of the yellow wires has a short piece of blue sheathing around it, the other two do not. I wondered why that was on the one wire and thought it must have some importance. So this yellow wire with the blue sleeve on it goes to ground? That solves one of the issues. I will just have to trace the three yellow wires coming out of the harness to see which one goes to ground. I take it, then, that the other two yellow wires can be connected to either of the remaining two yellow wires coming out of the harness. Sorry to make this possibly more complicated than it is, but I just want to be sure I don't have something wired wrong and burn up the new stator! Thanks so much for the help. I will work on it some more today and see if I can sort the rest out. I'm not sure of the brand of the new stator I got from Taffy but I think he said it was from China, since he seems to think they are actually one of the better ones now to replace the originals that all go bad, at some point. Regards, Steve
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November 10th, 2017, 01:46 AM   #4
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Hi

The stator that you got it's a electrex or hpi.

Taffy in the old days told very bad things about them, but it's selling them now. He says now they have evolved ?? It wouldn't be my first choice but hope everything works fine for you.

I would like to help, but would be essential that I knew exactly what's your bike (year).


ZAGA
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November 10th, 2017, 02:52 AM   #5
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I have wiring harnesses here that are for sale. we prepared them ready and then everyone lost my carefully coroborated info.

I can't believe you have 'special' wiring'. just don't believe that. if I was there I'd soon get to grips but there we are...........

the most important thing is to connect the 3 wires from the stator to the 3 at the coil and then it should fire. after that, everything else is a bonus!

there are three basic electrical diagrams. with battery, without battery. MX.

Taffy
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November 12th, 2017, 03:33 PM   #6
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Hi Taffy, Like I said, the black, green, and red wires going to the coil from the stator were no problem (self explanatory) and the wires to the e-start/kill switch are done (and working). The only wires I am concerned about are the 3 yellow wires connecting from the stator to the reg/rec. I don't mean to beat a topic to death, but just don't want to ruin any of the new components by having these mismatched. If you read the previous messages, which I assume you did, it sums it all up. To recap: three yellow wires from the new stator (two plain, one with a piece of blue tubing around it) and three yellow wires from the reg/rec that are all the same (no different markings at all). The only question I have is: does it matter which yellow wire goes to which yellow wire when plugging them together. If not, I am good and can get on with the rest of the bike. I just find it very odd that the yellow wire that has obviously been marked to be different ( with the blue tubing) wouldn't have to be plugged in to a certain wire from the reg/rec, but maybe that is the case.? Thanks for any clarification you might give. Regards, Steve
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November 13th, 2017, 01:41 AM   #7
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the original SEM unit has two yellow and a sky blue so that is obvious but the Electrex have three yellow. maybe you have a third option I've not heard of?

anyway, if you have three yellows you don't have to worry, basically someone is "pleasing your mind" a bit like a placebo....

that means one yellow (with the blue tape on it) goes to earth.
another goes straight into the rectifier. the box is colour coded on the back.
the third will join a red wire that is going backwards and forwards trying to feed live into all the units and switches. the connecting point will be somewhere inline with the front of the carb towards the front.

Taffy
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November 13th, 2017, 09:00 AM   #8
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OK, Taffy, sounds reasonable. This is the new unit I just got from you. So, if the yellow wire with the blue sleeve on it goes to ground (earth) and one of the other (non-marked) yellow wires goes to the red "feed " wire and the remaining yellow wire goes to one of the three yellow wires coming out of the reg/rec, what do the other two yellow wires coming from the reg/rec go to? Is anyone else reading this as confused as I am? Do these two yellow wires plug into something else? Once again, sorry that I am having such a time with this. I readily admit my shortcomings when it comes to wiring, but I had no idea I was this bad!
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November 13th, 2017, 09:48 AM   #9
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a rectifier has no wores coming out of it. this goes for all those up to and including 2002. in 2003 they made the reg/rec one unit and yes, there are 5 wires coming from this. three yellow, a black and a red.

everything before 2003 therefore has no yellows anywhere whatsoever except the 2 or 3 but a bluse sleeve) from the stator.

you sort it out!

Taffy
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November 13th, 2017, 11:53 AM   #10
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Thanks. I won't bother you again.
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