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September 2nd, 2018, 01:51 PM   #1
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Head/taillights barely works with battery connected

Hi!

Bike is FE450 -06 with 550 -03 engine and swapped electrics between them after this guide: Engine change 650
SEM stator values checked out last time I measured them.

When I have my battery connected my headlight and taillight barely works,
I have to rev quite a lot for them to shine at all. The indicators work fine though.

If I disconnect the battery the lights work with some revs but I need to rev it quite high for them to shine properly and the indicators only work sometimes.

Also my e-starter will only turn the engine one cycle.
Might have to do with the fact that I picked a 6Ah battery (completely new) instead of the recommended 8Ah.

Am I look at a bad ground or maybe a faulty voltage regulator?

Best Regards
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September 3rd, 2018, 01:05 AM   #2
ede
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Hi The TaXUS,

maybe it's two separate problems!

1. Lighting
If I'm not mistaken:
  • 2006 Kokusan Generator: 3-Phase, 150W
  • 2003 SEM Generator: 2-Phase, each 70W

Therefore both bikes had different regulator-rectifier. The newer 2004+ regulator is an all in one device, while up to 2003 the bikes had 2 different devices.
Up to 2003 the regulator/rectifier feeds the battery, the blink relay and the horn. The second phase is connected to a regulator, and direct feeds the brake light, rear light and front light! That means the rectifier is one phase only. You can rebuild the old setup on the newer wiring harness and your output should be better. But try it with a sample first before you cut all the wires, make sure the error is not somewhere else. Make sure your ground is good - that's important for every setup!


2. E-Start
The E-Start always has problems turning the engine over. There is lots of threads available about the issue. Most common is the decomp-mechanism on the camshaft gear and weak starter motors. This issue is not directly related to your wiring. You can cross check that when you wire your starter to an external 12V car batterie. Then both harnesses are separated. If you want to start it on the button - it seems to be an endless fiddle to make it reliable. Read the other posts about it first.

Regards,
EDE
Thanks from tourist and TheTaXUS
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September 3rd, 2018, 11:11 AM   #3
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Originally Posted by ede View Post
Hi The TaXUS,

maybe it's two separate problems!

1. Lighting
If I'm not mistaken:
  • 2006 Kokusan Generator: 3-Phase, 150W
  • 2003 SEM Generator: 2-Phase, each 70W

Therefore both bikes had different regulator-rectifier. The newer 2004+ regulator is an all in one device, while up to 2003 the bikes had 2 different devices.
Up to 2003 the regulator/rectifier feeds the battery, the blink relay and the horn. The second phase is connected to a regulator, and direct feeds the brake light, rear light and front light! That means the rectifier is one phase only. You can rebuild the old setup on the newer wiring harness and your output should be better. But try it with a sample first before you cut all the wires, make sure the error is not somewhere else. Make sure your ground is good - that's important for every setup!


2. E-Start
The E-Start always has problems turning the engine over. There is lots of threads available about the issue. Most common is the decomp-mechanism on the camshaft gear and weak starter motors. This issue is not directly related to your wiring. You can cross check that when you wire your starter to an external 12V car batterie. Then both harnesses are separated. If you want to start it on the button - it seems to be an endless fiddle to make it reliable. Read the other posts about it first.

Regards,
EDE
Hi,

thanks for answering.

1. I have two of this one from when I bought the engine https://gyazo.com/5f14013acf8d119229920f4331e4eaae
Is that the one you are referring to and the one I should wire in instead of the newer one? After checking for bad ground of course.

2. The starter is from the newer 450 engine and worked fine with that one. I tried jumping the battery and it turned it over, although it was a while ago before I had assembled the tank and the rest of the wiring so if it would start it I don't know. Will try later this week since I have taken a few days off.

Best Regards
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September 4th, 2018, 12:21 AM   #4
ede
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Hi,

your picture looks like the newer regulator that fits the kokusan-type stator. I attached a pic of the old setup for the SEM-type stator (OEM, runs fine on my bike --> ignore the bad cable connection, I already made them like new again).

Regards,
EDE
Attached Thumbnails
Head/taillights barely works with battery connected-regulator-rectifier_small_text.jpg  
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September 5th, 2018, 08:12 AM   #5
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Originally Posted by ede View Post
Hi,

your picture looks like the newer regulator that fits the kokusan-type stator. I attached a pic of the old setup for the SEM-type stator (OEM, runs fine on my bike --> ignore the bad cable connection, I already made them like new again).

Regards,
EDE
The one I am currently using is this one: https://gyazo.com/29bee0463b3e8fed282b6018432ec1e8

According to the parts catalog the one the -03 is using is the one I screenshoted before.
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