Hello everyone,

My '09 KLX250 has a charging problem. I drive two times 10 km to my work everyday and need to put it in the charger at night otherwise it dies halfway or after two days.

Second, the cable (white positive) from the rectifier touched the chain and was damaged, half of it remained. The starter solenoid melted where the white positive entered. There was no power when turning the key. Main fuse didn't blow out. I connected the white cable again and repaired/cleaned the starter solenoid and it starts again. The charging problem remained.

I do not know if the charging problem had to do anything with this!!
Maybe this ruined some other part?

I did a lot of tests from the manual but i still do not know what the problem is. First of all, my battery is one month old, i replaced it because i thought this was the problem, not.

My bike makes about 13.5 volts at idle but it drops when it makes more rpm. For example, it makes 13 volts at 5000 rpm, manual says 14v at 5000 rpm. It must drop below 12.7 somewere because the battery drains.

I did the alternator output test on the yellow wires. The manual says it must be 45v or more, i read 75v. Stator coil resistance multimeter (200 ohms) indicates 1.6, manual says between 0.3 - 1 ohms. (test range 1 ohms)
Is this reading correct, i only have the 200 ohms test range on my multimeter? I found no shortages or breaks in the stator coils, diode test between 3 yellow wires was 003.

Also I checked the cable connecting the rectifier with the alternator.
I did the checks from the manual and got no strange readings.
Diode testing: I read 597 - 610 on all six tests. (3 pins on pos / 3 on neg)

My quenstion:
What could be faulty, the stator coil, the rectifier of something else?
Could the damaged positive wire have something to do with the charging problem?
What else can I check to find and fix the problem?

Thanks for your help!!!

 

Welcome to the forum. The low charging voltage is a common issue. Additional ground and battery wires help significantly. Discussed here:
https://www.kawasakiforums.com/forum...olution-43856/