i have now checked the stator with in spec and nothing going to grnd and all 3 coils with in spec
tested ignition coil just to be shure also with in spec.
the only wire i am unsure of is the brown wire going from the voltage regulator, any ideas?

 

Update.....
i found the problem it was the brown wire going to the VR did not get current battery voltage. found a connector next to the battery that had smurf dust in it that ate 2 wires wich came off. replace the connectors and VR is now working normal. (13.XX volts)

added pic of the connector

 

Nothing like a low/no cost item to repair versus spending a bunch of money on parts that don't change the problem.

 

actually got a used VR from ebay on my shelf now but oh well. now the charging system seems to work and just need few things to finish things up next weekend.

 

Hoping I get lucky and someone who knows this info is still lurking on this thread.....

I've been through countless web pages and the KLX250S manual and cannot find the answer to this question:

1. For the rear wheel (18") lace pattern. The OEM part states there are two rear spokes, one long, one short. The OEM parts say LH (left hand) and RH (right hand). In the diagram it shows the LH spoke on the right side of the bike and the RH spoke on the left side of the bike (orientation is as if you are sitting on the bike) Now i assume that LH means on the left side of the bike and the OEM parts diagram just has them on the page in no specific order. What i'm having trouble figuring out is: What is the rear 18" wheel spoke pattern for a 2015 KLX250S? I have watched a ton of youtube videos and most/all of them say that the longer spokes goes on the inside of the hub and the shorter ones on the outside of the hub. Im assuming since the OEM parts say LH/RH that its actually not the case for the KLX and the longer ones go on the LH side of the hub and the shorter ones go on the RH side of the hub. (unlike the videos that have both long and short on either side, with the long spokes being closer to the middle of the hub)

I have actually assembled the wheel/spokes/nipples in the orientation above. With the long spokes on the LH side and the short spokes on the RH side. I still need to dial it in, but so far it actually looks like it is correct. Im going to mount the rim (without the tire) on the rear of the bike and see if the sprocket and rotor line up with the front sprocket and brake caliper. I just didn't want to start dialing in the rim if I actually didn't lace the right spokes up.

Really sorry for the long winded explanation. I have done a bunch of research and still cannot find the answer. This is my last attempt before i try calling a Kawi service center.

disassembled rear wheel

after assembling the long spoke on the LH side and short spokes on the RH side.

Thanks!