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X2 on the voltage reg!!
 

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Inspect wires for cracks or worn thru areas. You'll be buying a new magneto shortly unless you locate the damaged insulation. Places that the wire will move are good places to start, such as where the hood hinges or the handlebars rotate. Also, where the wires exit the engine case, they should run through a plastic or rubber grommet of some kind, definitely check there, not only for a 12v to ground short, but between wires as well.

If you have electric start, (or a 12vdc source with some simple backfeeding) you could turn your light on (without engine running and at night) and wiggle the wiring harness starting from headlight and continuing back from there, and hope to hear/see a spark. the spark will be your short. This can damage your magneto tho, a visual inspection would be better.

If you're absolutely certain your wires are 100%, move on to voltage regulator / diodes, or magneto diagnostics.

Intermittent electrical problems are a nightmare, I wish you luck.

nakedandfam0us said:
If you're absolutely certain your wires are 100%, move on to voltage regulator / diodes, or magneto diagnostics.
okay maybe start with voltage reg. haha cheers
 

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Discussion Starter · #5 ·
Auto part Machine tool

Thanks for the help voltage regulator, It was the problem. The lights are still not that brite my brother wants to jump the 2 outside lights "hi beam" to the center light because it a hi low beam bulb and does not seem to go in hi. He wants all 3 lights on and the middle to be in hi.


Main chain drive was so far out of adj. it jump off while in reverse and broke the chase at the bottum. Forcast alot of snow tonight , look for parts saturday afternoon[:(]

Thanks again for the help
 
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