Killer's XL250

killerx

Been Around the Block
Picked this up a couple of weeks ago. Have most of the missing pieces, wiring harness is a mess, but it runs.
Planning on a period Baja/Cross Country build, Vesco tank, Petty style fenders, brighter/bigger lights.
Does anyone know if I can convert the electrical/charging system to 12v and leave the ignition system stock, or would it be simpler to go ahead and change the Ign. system also?
it does run now with no battery in it.
This will probably be a slow build, at least until March when the weather starts to warm, and lights a fire under my ass.

This is how it looks now.
20201106_100633.jpg
 
Last edited:

Luugo86

'73 CB350, '78 XS650 Cafe Killer
Great score.. if you are are replacing that stock tank and have no plans for it, send me a PM dude.. I would be a player on that for sure.
 

Maritime

Over 10,000 Posts
I think you can convert to 12V and keep the 6V coil and use a resister, there are threads here on the CB/CL100/125 and the am almost sure the XL100/125/200/250's are the same thing.
 

killerx

Been Around the Block
I'll have to go over the wiring diagram again. Previous owner started to build a new wiring harness. There is no battery but it runs, so that makes me think it has a magneto for the ignition, separate from the alternator.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Nice choice for a Baja bike.
The stock system has an ignition coil and an charging coil.
Mine always ran with the dead battery it had. Never had any starting issues.
Electrixworld has a 12v upgrade system for ignition only or both charging and ignition.
 

Maritime

Over 10,000 Posts
Nice choice for a Baja bike.
The stock system has an ignition coil and an charging coil.
Mine always ran with the dead battery it had. Never had any starting issues.
Electrixworld has a 12v upgrade system for ignition only or both charging and ignition.
Ok so not exactly the same as the others.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Not sure if this is any help but I traced the wiring diagram and made a colour version.
XL250 wiring.png
 

killerx

Been Around the Block
So, I've been putzing around with the XL.
Couldn't get the clutch adjusted so it would fully disengage or not slip, it was either one or the other.
Pulled the adjusting plug, which had been replaced with a brass plug, held in by RTV and a screw. That's when I noticed the shaft would move every time I pulled the clutch. The case was worn out. Not sure why the 250 cases are so expensive, picked up a case for a 350 for $30. Got it back together, seems to be working right.

Now, I'm moving to the electrics and found this(1st pic) wire colors are not correct.
Did the tests in the 2nd pic and it looks like I need to replace the stator.
 

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Rider52

Over 1,000 Posts
I never ran lights or a battery on my XL250 so I can't help with a 12V conversion. Good luck, looks like a great project.
 

teazer

Over 10,000 Posts
DTT BOTM WINNER
Looking at that wiring diagram, the ignition is independent of the battery/charging/lights circuit but is old fashioned using points and condensor to fire the spark.

That Electrexworld system should be a nice upgrade though.
 

killerx

Been Around the Block
The Elextrexworld kit is pretty much what I had in mind.
I'm afraid to see what shipping to the States is.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
I have also heard of a swap you can do with the ct110/c125 coils. Not heaps of info around from what I could find. Might work out cheaper.
 

teazer

Over 10,000 Posts
DTT BOTM WINNER
Surely you could get the charge coil rewound and get a solid state regulator/rectifier from Sprakmoto and change the bulbs and coil and no need to do anything to the ignition if you don't need to.
 

killerx

Been Around the Block
I picked up a digital multi meter and the numbers look better. Tomorrow is a huge Charity ride benefiting local kids, sxo thats what I will be doing.
Sunday I will do a running test and see what the AC output is and go from there
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
I did a small change on mine and put the coil output for the headlight through a newer Reg/Rec along with the charging output. The headlight is then changed to the battery driven 6v. Yet to test it but hopefully it will provide a better charge at 6v as stock anything the headlight didn't use was wasted.
 

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