Hey Guys it has been way too long, well long story short I finally got a replacement radiator for my DS that I have been putting off since sept (2005 ds650X), and went to get her up and running today. Of course the battery was dead and I jumped the bike off of a battery I had sitting in the garage. Bike fired up great and was running with no problems, started tuning in my new needle for my lectron, Muplitple starts and adjustments to the needls, then the positive cable slipped off my battery and the bike died. I put it back on and would not fire, decided to disconect the jumper cables as I dont like what it is doing, throw the little trickle charger on and now all I get is the neutral light that comes on, nothing from the tach nothing from the ignition (prior to this with this charger tach would light up bounce up to 5K then back to zero and starter solenoid would click) Put a different charger on the bike and tried to turn the headlights on, they got super bright then burnt out. Clearly I effed somthing up here but am not sure what, any ideas on what I am looking at replacing due to my dumb move of jumping the bike?

 

I dont think jumping the quad was the problem, the starter will only take what amps it needs to turn over, whether its from the ATV battery, or a battery from a Mack truck. Sounds like you had a short, and either took out the cdi, or the rectifier (why your headlight went REAL bright, no regulation of stator output). Not sure how to test them, Lynn Edwards on the forum is our resident wiring/electrical guy, hopefully he will see this thread, or you can look him up.

 

ok little update, unplugged the voltage regulator/rectifier (goofy looking metal box with the fins), was able to get a charge in my battery after adding some distilled water to it last night, will deff replace that. But was able to get it to turn over.

Pulled a plug wire to check for spark with my Big Gun CDI and no spark.....so its dead I assume. Plugged in the stocker and she fired right up as I was checking for spark so Big Gun CDI is deff bad.

Is there anyway to check the regulator, or should I replace it just to be safe. I dont want to ruin another CDI. Bike fired when it was unplugged, I shut it down imediatly but felt real good to hear it start up. I hate electrical stuff. Give me mechanical anyday of the week. But hey at least I am learning something new.....sometimes at a price to the pocket book but hey live and learn.

 

You cannot do a static (regulator removed from the quad) test on a regulator/rectifier. It needs to be plugged in with the bike running to test it.

Inspect the wires where they go into the rectifier. I believe it's a common problem for the wires to flex right at the strain relief over the years, and eventually fatigue (bend) and fail. If it has happened to both the hot and ground wires and they are allowed to touch, it can possibly melt the wires and pop the fuse, as well as destroy the internal circuits of the rectifier.

I'm not sure, but it does kind of sound like the rectifier is bad, allowing too high of a voltage that killed your lights and your CDI. If you run the bike again with a bad rectifier plugged in, you might risk killing your stock CDI. If you are willing to risk it, hook up a volt meter across the battery BEFORE starting the bike. Crank it over and see what the voltage is AT IDLE. It should not be more that 14.5 volts ever, otherwise the rectifier is bad.

You may just want to try to pick up a used one on fleabay or somewhere else. Last year when I needed one, I cross referenced part numbers of the recitfier and found a used one off of a sea-doo that would work. I think I had to cut and splice my wiring harness on, but I got it really cheap ($25). Dealer price ranges from $130 to $170 for a new one.

 

Does anyone know if a regulator off of a early model like 2000-2003 will work? My bike is an 05 and has the round plug. Can I just splice my connector on to an early model one?

 

Yes, the regulator off of any year DS650 and some Sea-Doo watercraft will work. Like you said, you may have to splice your own connectors back on.