these wirings are strange. my quad has the on off of headlites via the switch on top of throttle. orange goes to it then from switch to high low. With mine the diagrams were worthless! everything ties into a cluster *** of wiring. I had to do low then high and make sure everything worked before closing up headlight. if u really need it i could take a few pictures of what is involved with this and hopefully shed light on ur situation

 

Well I am missing the rectifier as of now, so I'm trying to figure out if the rectifier hooks up on the ground side of the headlight or if it hooks up between the mag/switch side or if it tee's into the mag/switch side.

 

I'll try to take a pic of the rectifier tonight. Got a work realted dinner meeting, so depends on aldult beverage consumption.[img]i/expressions/beer.gif[/img]

 

I don't know how else to put it.... The orange goes to a switch.... Any switch you want. Go to walmart n get a switch with 2 termianls on it. Hook the orange to it. Use the kill switch if you want. Just hook the orange wire to any switch you want to use for lights.

Now, I have no clue what color wire you have coming out of your switches. But, whatever wire you hook the orange to, you need to find the other side of that switch and hook the gray to that. Also, hook the regulator to that too.

The orange has to go to a switch though so it can be turned off when not in use. You cant run the lights without a regulator or you'll end up burning up your lights or worse.

I'm pretty sure its a regulator and not a rectifier. A recitifer turns AC into DC (we dont have alternators - we have magnetos). A regualtor just makes sure your voltage never gets higher than 16 volts (or something like that). If you run w/o the regulator, your voltage could go as high as 50 volts. V=IR says if R stays the same and V goes way up, then I goes way up. If I goes way up, you'll fry the lights and possibly the lighting coil.

 

<div class="FTQUOTE"><begin quote>Originally posted by: PoolGod230

I'll try to take a pic of the rectifier tonight. Got a work realted dinner meeting, so depends on aldult beverage consumption.[img][/img]</end quote></div>

He knows what it looks like coz he found a pic on ebay. The only thing that is not clear in the pic is that the wire is gray (grey - whatever - the books says its gray).

 

Well I got the 86 sport.. no battery.. kick start..

I already played with a multimeter on the switch, grey on the light switch feeds white or yellow (low or high)

I just need to know how that regulator fits in. Is it wired like a wastegate on a turbo car? just tap into the orange wire so it can bleed the excess voltage? or is it in-line like on my 6-volt dt, eg mag goes to white on one side of rectifier, and red feeds headlight /battery.

 

Dont hook the regualtor to the orange. Hook the regulator to the grays. If you hook the regulator to the orange, it will always be regulating the voltage from the magneto and you can never shut it off. That will pull juice out of the mag for no reason. It just a waste. It will slow you down a bit too. No need for that.

Maybe later I'll draw a pic n scan it n post it.

 

And the solid black and black /white stripe'd wires should all be bolted to the mounting bolt holding the regulator..correct?

If thats it and the grey wire just splices withthe grey switch and orange mag wire I'm all set.

 

Thats why I'm going to buy that switch, that way you can cut the voltage right at the bars and keep the wiring simple..

Can someone take a picture of this "switch" besides the one I have?

I dont have a key or anything. Just a high low run/kill

I would just buy a switch at walmart but I need ti to be insulated, I dont want to cross a stream when im trail riding and have the lighting coil ground out raw and then its junk..

 

ill post a pic of it http://cgi.ebay.com/ebaymotors...rdZ1QQsspagenameZWD1V

not a clear pic of it but there it is...... factory on off switch. both my quads have same one