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1975 Suzuki TS250 electric problems...?



I have a 6 volt battery/system in my bike. The turn signals on my Suzi stay on but won't flash on and off. I am using 6 volt lights in the signals. I have tried both a 6 and 12 volt flasher, same results; lights stay lit without flashing.

My headlight keeps burning out, I have tried both 6 volt and 12 volt bulbs. 6 volt lights have no chance. 12 volt bulbs are fine when bike is idling, when I give it gas the bulb burns brighter and brighter until it blows.

In the headlight bucket, the electrical hub, there are 3 wires that are not connected to anything. 2 are attached to the bolts that attach the bucket to the front forks, ground wires I'm assuming, but not connected to anything. The 3rd wire is a brown white striped wire with double female connectors at the end, not connected to anything.

I tested the voltage at the signal lights before and after replacing a blown 2 olm resistor with a new 2.4 olm resistor. It read 7.5 volts before and after replacing the resistor.

IDEAS?

I had a 74 TS 250, Iwish I could remember more about it, but, 30+ years is a long time. Anyway, as far as I can remember the bike didn't really have a voltage regulator, as Guardrailjim suggested I think it was just a balanced system. Just about every 6 volt bike I have ever worked on has poor directionals, frequently they will need the engine running in order to little extra voltage in order to flash. Regarding the wires in the head light bucket the two attached to bolts are ground wires, usually for the turn singles, check to see what your present directional grounding method is. Regarding the headlight bulb, try getting the stock specified bulb for a replacement, like I said I can't remember what that bike had, but, if the head and tailight are on an AC system the bulb may not be your ordinary 6 or 12 volt bulb.
Regulator assembly.

http://houseofmotorcycles.bikebandit.com...
wiring Diagram....email me will send it to you ... TS250

easygoing157@hotmail.com
I was going to say the regulator, but "gdwrnch40" beat me to it LOL
--Put a volt meter at the battery and rev the bike. Over 7.5 volts and the regulator could be bad.
--Make sure the battery is making a good connection to ground.
--Bikes with 6 volt batteries usually run on a balanced system. If the battery is removed, the excess voltage of the charging system would be directed to the headlight and burn it out. A dead battery (or one that won't take a charge) - same thing.
--If the battery was weak, or not making a good ground, the flasher relay won't work properly.
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