hi all i have a 2006 250 baja wilderness . the problem is it is not charging. i was wondering if anyone has had or seen this problem. or if anyone knows where i can get a good wiring diagram or diagnostic flow chart.
any help will be much apreciated . thanks

 

For a wiring diagram go to:

www.highrpmracer.com

Search for "Baja 250 wiring diagram".

Just looking at the wiring diagram I think there is a mistake. It shows two yellow wires from the stator, but I'm pretty sure there is three since most 250cc stators have a three phase output.

Testing the charging system is easy:

1) Start up the quad, turn off the headlights, and rev the engine up to a medium fast speed (3000 RPM).

2) While the engine is going fast measure the DC voltage right on the battery terminals. You should get 13.5 to 14.5 volts. If you do then your charging system is working.

3) If the battery voltage is low, monitor the battery voltage as you shut down the quad. Does the voltage drop? If so it is possible that your battery is so seriously dead that it is dragging down the quad charging system so that it can't get up to 13.5 to 14.5 volts. Try charging the battery with an external charger (2 amps max charge current) and see if the battery will hold a charge.

4) If your battery is good but not charging, unplug the regulator. Switch your meter over to AC volts. With the engine idling measure the AC voltage between all three yellow wires in the harness. All three should read about 25 volts AC. Note that you should be reading from yellow wire to yellow wire, and not yellow wire to ground. If it reads OK here then your stator is OK, and the regulator is bad.

 

I thank you for your help. tested the output as you had suggested and found approx 22 volts. tested output side and found nothing also during the testing the regulator got very hot. so now to find a regulator i will try my local dealer first, oh and by the way you were right about the 3 wires and not 2 also mine where white not yellow. again thank you

 

one more question , well one for now anyways . would there be any problem with running the quad with the regulator disconnected untill i get new regulator . i know it runs but was just wondering if it will cause any harm?

 

Nope. It will not hurt a thing as long as you remember that all the 12 volts stuff is running off the battery and draining it. That means each time you start it the starter motor will pull down the battery charge a bit. Each time you apply the brake (and light up the brake light) the battery gets drained some more. Leave your headlights off of course.

The ignition system runs off its own supply coming from the stator, so it isn't loading the battery at all while you're driving around. No worries there.

You want to make sure that you promptly charge your battery back up using a 2 amp motorcycle charger everytime you're done riding for the day. And if your going somewhere deep into the wilderness go with two quads and a set of jumper cables.