KDXRIDER.NET

Hi all,

It's my first post here so I'd firstly like to say thanks to all the great people here who have provided me with some very good information.

I've got a 97 KDX200 Australian spec which I'm part way through restoring. I have a question about wiring, which I realise is likely to be different than most of the bikes on here but here goes;

I have 5 wires coming from the magneto- 2 pick up wires (running to CDI) and 3 yellow running to the regulator so far so good.

From regulator I have 3 wires- 1 common ground and 2 white wires (1 is slightly thicker than the other)- here's where it gets interesting

If I connect the thicker white wire to the key mechanism which provides power to the coil- I get spark, the bike sounds like it wants to run but just cuts out after I stop kicking.

If I connect both white wires going through the key and back to the CDI the bike will run fine. No white wires connected and I get no spark.

Anyone have any idea what the difference between the two white wires is? I was thinking one would be power to ignition and 1 would be power to lights but that doesn't seem to be the case.

Cheers

If no one is able to help before the weekend, I'll be back at home with my 97 KDX200 (road registered in Australia) and can have a look for you

Awesome! That would be very helpful. I'm wiring up a headlight and tail light atm, just want to make sure I'm not taking power away from the coil.

any chance both white wires are both sides of the key ?

if you connect the white wires to each other without the key does it run ?

This is what I have atm, I had to change all the white wires to pink so they'd show up. From what I can tell this is similar to factory set up as all the wire colours are matching. I'm still unsure about the two white (pink ones coming out of the reg though).

If I connect the two white wires together without connecting to the key I lose spark.

Got home tonight and haven't had a chance to look at my KDX yet, I'll try have a look tomorrow.

OK, so there are 2 magnetos in the KDX, one for the CDI and one for lighting ("the lighting coil") From the drawing that you have there, somehow they are connecting together...I don't think that is correct at all. Seems the Green wire should go to the Key switch, then to the CDI. It seems as though those Pink wires are powering your CDI instead of the (intended) Green wire.

old thread but just to keep all relevant AU road legal wiring stuff together, the rectifier/regulator in an sh548-12 unit and its used across the kawasaki range using the oem numbers 21066-0027, 21066-1052 and 21066-1038. the 3 versions appear to be interchangeable and are used on these models -

KAWASAKI ALL-TERRAIN VEHICLE (ATV) KLF220 BAYOU 220 215CC 1996-2002
KAWASAKI ALL-TERRAIN VEHICLE (ATV) KLF250 BAYOU 250 228CC 2003-2011
KAWASAKI MOTORCYCLES KL650 TENGAI 651CC 1990-1991
KAWASAKI MOTORCYCLES KLR600 KL600 600CC 1985-1986
KAWASAKI MOTORCYCLES KLR650 KL650 651CC 1987-2007
KAWASAKI MOTORCYCLES ZN1300 VOYAGER 1300CC 1983-1988
KAWASAKI MOTORCYCLES ZR550 ZEPHYR 553CC 1990-1993
KAWASAKI MOTORCYCLES ZX550 GPZ 550CC 1984-1986
KAWASAKI MOTORCYCLES ZX750 750R GPZ 748CC 1983-1985

21066-1038 seems to get the most hits on ebay and aliexpress and there are aftermarket alternatives available.

the klr600 is prolly the best reference to compare to the AU models that i have been able to find,



the internal wirhing of the R/R os below and consistant with the kdx and klr schemes.


consistant with sammys comments there does need to be 12v wired to the sensing terminal for the regulator to run, here is the internal circuitry of the r/r.


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The correct wiring diagram for the Australian models is here for future reference. I am currently having a few issues with mine also.