I own a Baja 150 and the lights quit working. The headlights were really dim even with the RPMs up last night, but today I don't see anything. I checked for DC voltage on the red wire on the regulator/rectifier and it was zero. Is this AC or DC? The buggy will start and run fine. I have not modified any of the lights or electrical. Where does the voltage for the lights come from, what color is the wire? I also noticed the plug on the regulator/rectifier had been hot and melted some, what would cause this?

Thanks in advance, Luke

check the voltage coming from the stator

on the three wire plug coming from stator yellow should be your lights and choke,white should be for charging battery, black is ground
those get check with meter set a AC voltage.
i would check that as BIGE said to see if you still have power from stator.
the melted plug could have been from a loose or corroded connection,also check your grounds
if you have power from stator the rectifier regulator may be bad again check your grounds.my self i had a loose connection and my regulator rectifier once was arcing melting my plug a little and cause it to blow my bulbs out in head and tail light
white for charging battery ac power going in regulator rectifier and DC coming out on red wire for battery.
hope that makes since.

pud

Thanks guys, for helping diagnose this. I still have no lights, and it appears it is not choking also. I also checked the battery voltage running and not running and it remains the same 12.12v. The buggy does start and run fine.

Here are my findings.

I have roughly 14-15v AC on the yellow and white wires from the stator, and when I give it a little gas the voltage shoots up 20-22v.

The ground from the battery is secure to the regulator/rectifier, what other grounds are there?

Are the lights and choke AC or DC? Are they ran straight off the yellow stator wire????

What else can I check, what is the problem?????

Thanks again, Luke

yes your lights and ckoke run of AC power dim at idle rev engine light get brighter.
the yellow,white black wire from stator after plugged in branch off in wiring harness going to rectifier regulator.
on my buggy i have two grounds one from battery and a medium size ground wire.they bolt down to my cvt cover.
the medium size ground picks up the rectifier regulator,stator,ground for choke resister,coil and lights.they go into harness and soddered together.not sure if yours is like that but it gives you some kind of idea.
from what you said it sounds like maybe you just have a bad rectifier regulator.could have went bad or loose connections caused your problem.i had to tighten up my connectors in plug for rectifier regulator so they would stay tight and make good connection.luckly i caught mine in time before any damage was done.

pud

Thanks, I will look again at my grounds and check my connections. I still don't understand what the regulator/rectifier is doing for my lights, when they are connected to the yellow stator wire before it gets to the regulator/rectifier. I know the regulator/rectifier converts the AC voltage to DC, then regulates it at like 14.5 volts. I just don't get how it is wired in the system to perform its job. Also, shouldn't I be seeing a higher voltage on the battery terminals when it is running? Is this also a sign of a bad regulator/rectifier?

Luke

The rectifier on your buggy is strictly for charging your battery. Your lights and choke run off the stator AC voltages. If you are getting AC at the stator, you should be getting DC out of the rectifier.

peter i was messing around this even and opened my wires back up.
i was telling the wrong info yellow is for battery and white is for lights.
so i'm sorry for that like to be wright or try to be.sorry if i confuse any one
its not that i never believed you but i have brought this up before.my lights are wired into the regulator/rectifier.maybe the reason for this is that i have a light switch you can turn the lights on and off.maybe thats the reason for them to be wired in, power has to go some where when switch is off.
not trying to confuse him the lights are AC,probably not ever bodys buggy is wired like mine.
here are a couple pictures
pud

I still don't understand this wiring, but I believe you guys! Why don't I have lights or a choke, I have AC voltage coming from my stator? Also, shouldn't the voltage be greater on battery posts with the engine running?

I have owned this buggy for over a year with no problems, this problem just developed a few days ago.

If your rectifier looks like the first picture, it is a typical GY6 rectifier only for battery charging. The second picture is of a dual output regulator/rectifier typically used for 250cc buggies. Your switch may be turning on AC or DC voltage (you would need to measure the output).