2006 wiring

[2stroke]

I have a 2006 Gasgas EC 300 and have two issues.

One is the headlight. A while back I got a trail tech x2 but could never get it to work. I traded emails and phone calls until they just stopped responding. Trail tech just couldn't figure out why I had voltage at the bulb, but it wouldn't work. I could get either bulb to light individually fine, but the problem is for a "high beam" with both bulbs on it wouldn't work. There was power to both bulbs, but what I found was not enough was getting to the small one. I now have it wired with a relay which has much less resistance than trying to go straight through a switch. I finally have both headlights working at once, but at very low light. Again, either bulb works fine individually, but with both on, the bike just doesn't put out enough amps to power them. This seems odd to me considering this bike should have come with a headlight, as well as it has all the wiring for tail light and presumably turn signals as well.

The second problem I have is the CDI map switch. I am under the impression all 2006's have dual map CDI, but for the life of me, I can't find the wires. The best I can tell its a black and an orange right from the CDI box, but mine has no such wires. Infact, mine is one piece with the wires molded in, and only one bundle of wires coming out.

[Neil E.]

2K2 (small dia ~35W) or 2K3 (large dia~75W) stator?
Jumper from your yellow wire at the regulator directly to the bulb terminal (ground the bulb shell to the frame). Run the engine; is the light brighter?

[Neil E.]

Are you using a motorcycle headlight bulb (35/35W) or an automotive bulb (55/65W)?

[2stroke]

I don't want to go pulling it apart again now as I have a race saturday. How can I tell which stator I have? I must have the small one since my headlight is rated at 70w. Whether or not that is with just the big bulb or both bulbs I don't know. Straight form Trailtech, "high mode" 70w, "low mode" 35w.

It looks to me each bulb is rated at 35w.

[Neil E.]

It's more likely you have the larger 2K3 stator. This has the trigger pickup located at a 2:00 position when looking directly at the flywheel. The smaller 2K2 has the trigger pickup at 10:00.

The Trailtech X2 headlight should at least run the low beam lamp OK. Does it work fine if you wire it directly to a car battery? This just confirms the product is OK.

Any broken strands in your wiring will hamper current flow to the light. You will have to check all the connections too. Also the ground has to be in good shape and attached directly to the frame.

[thumperflipper]

Here is how I wired my 07 with the X2. I have the 2k3 ignition. Always worked fine with AC power, high and low beam. (I have since converted to DC, thanks again to the forum member's input). Kind of wordy video, but the wiring comes in later...

https://www.youtube.com/watch?v=JLTPE5QY3KQ