ktom300

Try www.sudco.com. www.bikebandit.com is also a good site

Diagram has it listed as a rectifier and there's no cooling fins or method to sink heat. I think the battery is key in this circuit as a regulator and without it, the bulbs are subject to the max output of the magneto. Everything worked fine at idle except the flasher relay. Also, I found a 6 volt battery for RC around the house and it's enough to power the DC system with the bike off for trouble shooting. Confirmed the headligt does not power up with DC.

The battery thing makes sense so I ordered a new one. Can't hurt. One more question, if the headlight runs on AC then why did it blow out as well? Could the whole system be on DC and sufering from a faulty battery that's not regulating the voltage down? Thanks again Tom

So I have the wiring diagram from the manual and I blew it up on the copier. Hooked up almost all the wires (one has no home) and I noticed not all the colors match. In the end I have lights but everything appears to be running on AC so the headlight dims when blinkers are turned on or brake light is hit. Also, when you rev the bike up, the bulbs blow. My diagram does not show a regulator, only a rectifier so I'm stumped. Also battery is a loss (original from 1977) but this shouldn't matter right? One last symptom is the blinkers don't flash. Could this be because the flasher is hooked to AC also? Thanks, Tom

Thanks for the feedback here. Bike runs now and starts first kick no matter what. ODO says 376 original miles! Next question is with regard to the oil injection system. The headlight is off and the rats nest of wiring was mostly unplugged. I tried to match stuff up by color but the bike didn't want to keep running so I unhooked everything. Is the injection system 100% mechanical or is there anything electrical that would prevent the bike from getting oil from the injection reservoir? Is the electrical system smart enough to shut the bike off when it's out of oil? The reason I ask is because when I got the bike, brown and black/white were twisted together from the ignition. This caused the oil light to come on. Anyone have a scanned wiring diagram? thanks!!!

I picked up a 77 DT100 from a friend and he estimates it hasn't run in 15 years. To make matters worse, someone lost the key at some point and attempted to hot wire it and threw away the switch. Seems complete and I'm interested in fixing it up but I'd like to hear it run before I spend any $ on it. Can anyone tell me how to connect the ignition wires so it will get spark? It has four wires red, black, brown, and black/white. Which wires have to be connected in order to turn it to on? Thanks, Tom