Why do my headlights keep blowing out on my Tank Urban touring 250 scooter?

by Brian

Hi, I have a 2006 Tank 250 scooter that keeps blowing headlight bulbs and instrument cluster lights, the turn signals work, hazard lights work, brake lights work when applying brake, but no tail light.

I replaced the headlight bulbs, started the scooter and headlights started working, but started out kinda yellowish then for about 10 seconds seemed normal and then got extremely bright and blew out on both.

The person I got it from said he had the rectifier replaced on it, but said it was a six wire, from what little I could find on this model if I'm correct, it says it should have a seven wire?

I did find a melted small black plastic two pronged resistor plugged into a two wire connector that is of colors red and yellow, also replaced the headlight switch but still blowing bulbs, I can also unplug part of the rectifier and scooter will start but idles erratic, is it possible the rectifier or stator or both are bad?

I also noticed a black wire mounted on front fairing mount that is bolted to faring mount but is cut and I do not know what this would connect to. One other item is when the key is turned to on position the cooling fan starts operating and the temp gauge goes to hot instantly.

I'm sure I have a wiring nightmare of some sort... any ideas? Thanks for your time.

Comments for Why do my headlights keep blowing out on my Tank Urban touring 250 scooter?

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Jul 29, 2011
blown headlights
by: brian

I have since solved problem, It was the charging diode that was the problem.

Jul 28, 2011
Alternator stator assembly miswired
by: G

You mention a seven wire rectifier; did you maybe mean a seven coil alternator? The alternator consists of a source coil which is actually part of the ignition system, and several, seven on my scooter, power generating coils which, if wired correctly, will properly supply two distinct circuits; the lighting circuit (which does not control all the lights, mind you, but does control the exact ones you say blow out), and the charging circuit.

Unfortunately, at least one parts distributor, PartsForScooters.com, has sold defective alternators which are miswired, resulting in the exact problem you described here. You will need a known good coil (or at least known to have worked properly in the past, that is the coils are wound correctly and it is wired correctly, even if it may have developed a fault) in order to compare to the one presently in your scooter.

Possibly, if miswired, you will be able to understand what to do in order to reroute and resolder the coil leads to match the correct configuration.

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