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October 4th, 2009, 02:27 PM   #1
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Charging battery off the voltage regulator

Hi all,

Just obtained a converted 02 550FC to supermoto. My gripe is that the lights are running off of the alternator which is fine up until the bike stalls in the dark.The wiring used to make the conversion looks pretty much identical to the ones from the FE or FS bikes.

Been thinking of converting the wiring to run the lights off the battery, however when I measured the voltage across the battery while it was running, it was saying only 12.2V. Seems to me that the battery is thus not on a loop that comes from the regulator. It seems to be in fact a total loss system. Looking at the wiring diagram I have of the FE-FS, the only live and regulated connection I can see is in the ignition switch which I assume switches between the red/black to the DC current on the red/white cables. I should delve a bit into the wiring around the starter relay but my guess is that when it was converted, a connection was not made on the red/black to red cable.

I also noticed that on the back of the voltage regulator, the yellow cable was stuck in the left most pin. On the wiring diagram it shows it between the rd/white and brown cables. Would this have anything to do with my battery not being charged?


Any thoughts?


Thanks
George
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October 5th, 2009, 03:47 AM   #2
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Re: Charging battery off the voltage regulator

Originally Posted by Komatias
Hi all,

Just obtained a converted 02 550FC to supermoto. My gripe is that the lights are running off of the alternator which is fine up until the bike stalls in the dark.The wiring used to make the conversion looks pretty much identical to the ones from the FE or FS bikes.

Been thinking of converting the wiring to run the lights off the battery, however when I measured the voltage across the battery while it was running, it was saying only 12.2V. Seems to me that the battery is thus not on a loop that comes from the regulator. It seems to be in fact a total loss system. Looking at the wiring diagram I have of the FE-FS, the only live and regulated connection I can see is in the ignition switch which I assume switches between the red/black to the DC current on the red/white cables. I should delve a bit into the wiring around the starter relay but my guess is that when it was converted, a connection was not made on the red/black to red cable.

I also noticed that on the back of the voltage regulator, the yellow cable was stuck in the left most pin. On the wiring diagram it shows it between the rd/white and brown cables. Would this have anything to do with my battery not being charged?


Any thoughts?


Thanks
George
Hi George,

The best way to run your lighting off the battery is to run full power from the Alternator to an uprated Regulator Rectifier (Trailtech 150w).
To do this all you need to do is join together the 2 Yelows from the stator and along with the Blue feed these into the forementioned Reg/Rec then direct to the battery .
Then take a feed via a fused link from the battery to the ignition switch or direct to the lighting switch, now you can have a dead engine but retain your lights.
You will have to take a back feed to the brake light switch if fitted.

Regards

Sparks.
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October 6th, 2009, 04:18 AM   #3
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RE: Re: Charging battery off the voltage regulator

I was trying the same on my FE fully road legal 501 02 this weekend. Only got 3 wires to the bulb white / yellow & brown - 2 of which have continuity to earth. There is a blue wire in there but it's been chopped and sealed off ??think someone's been here before me....

Gave up after a while as it all works fine when running & was was keen to get out for a blast.

Just put on a new MF CTZ7s (or whatever) battery in an attempt to resolve the e-start issue. Keep you posted. Still have the original starter & all seems OK for now.
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October 8th, 2009, 12:49 PM   #4
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RE: Re: Charging battery off the voltage regulator

Hi guys thanks for the replies. Was wondering...would a >2004 stator fit into my 2002 engine? Been offered one off an FE and seems to me that if it does fit it would be pretty neat.
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October 8th, 2009, 01:14 PM   #5
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would a >2004 stator fit into my 2002 engine
no. 02 is sem and 04 is kokusan.
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October 12th, 2009, 04:33 AM   #6
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So I spent some time in the garage last night. Did some rewiring on the bike to run the lights off of the battery. It was a simple affair really. Put the second yellow cable that comes out of the alternator into the voltage regulator/rectifier on the leftest spade. Then ran a cable from the battery to the top yoke connected to a relay and fuse and then back to the original light circuit (red cable). The relay switches on the red/white cable so that the ignition switch turns the lights off. Will probably fit a load relief relay at some point but might not need it as the e-starter sucks donkeyballs anyway. However this mod made the cranking speed slightly higher.

My concern is that the stator I have might not actually be up to the task of charging the battery since it is a FC bike which has been converted.
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October 12th, 2009, 10:33 AM   #7
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Originally Posted by Komatias
So I spent some time in the garage last night. Did some rewiring on the bike to run the lights off of the battery. It was a simple affair really. Put the second yellow cable that comes out of the alternator into the voltage regulator/rectifier on the leftest spade. Then ran a cable from the battery to the top yoke connected to a relay and fuse and then back to the original light circuit (red cable). The relay switches on the red/white cable so that the ignition switch turns the lights off. Will probably fit a load relief relay at some point but might not need it as the e-starter sucks donkeyballs anyway. However this mod made the cranking speed slightly higher.

My concern is that the stator I have might not actually be up to the task of charging the battery since it is a FC bike which has been converted.
Hi George,

As long as you have a FE flywheel, it will do the job no problem, but like I said if you are running the lighting direct from the battery you will need an uprated regulator rectifier.
The weak link you have at the moment is not the stator but the original Reg/Rec.

Regards

Sparks.
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October 14th, 2009, 03:59 AM   #8
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Sparks,

I get your point. Would there be any reason, apart from the crimp connectors, why one would not be able to use a reg/rec from a bigger bike like a bmw or a honda?

Thanks

George
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October 29th, 2009, 11:12 AM   #9
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Did a few checks and I figure the regulator rectifier has given up the ghost....time for a new one so if anyone has a 2003 one let me know
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