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Klx grounding/charging problems
Topic Started: Aug 24 2017, 07:51 PM (822 Views)
Klxrider
Member
[ *  * ]
This topic has been covered here and there on the net and thanks to those of you who have written up your fixes.
The problem, in my case on a Klx250S (2009) is intermittent spark misses at high speed and a charging problem with the battery going flat in a couple of days. A voltmeter on the battery shows that the voltage (at about 12.5v) does not come up to a charging level of about 13.5v even when the engine is reved up. The AC voltage generated by the alternator was good, and so was the R/R regulator. A replacement R/R did not fix the charging problem. It turns out to be a grounding problem for the R/R and the solution is this.
Pull the plug off of the regulator, and extract the pin with the yellow/black wire from the plug. This is the ground wire. Solder a wire directly to the pin (that is the wiring harness pin, not the R/R pin) , re-insert the pin and ground the other end of the wire to the ground point just under the regulator where the battery ground is also connected. This should fix the problem. Here is a link to a page where the problem is described in detail.

http://klxworld.blogspot.ca/2014/03/rectifier-ground-mod-possible-fix-for.html
Edited by Klxrider, Aug 25 2017, 01:17 AM.
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