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May 18th, 2007, 12:54 PM   #1
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Lights burning out on 2002 FS650e

When I increase revs on the engine with lights on, they glow brighter with increasing revs until they burn out. I contacted DCR in UK and they suggested I modify wiring,
Stator blue lead connected to earth spade around regulator mounting bolt
Stator yellow(1) to yellow connector on rectifier
Stator yellow (2) to red lead in wiring loom
Regulator brown lead to earth
Regulator yellow lead to yell/brown connector of rectifier
Note this model has separate reg and rectifier.

Have done this mod but lights still blow. If I had a wiring diag I can follow it but DCR said no diags for 2002 are available. Should lights be connected to regulator or to battery? Battery seems to stay at 12.6V irrespective of revs.
Can anyone suggest something I can try, particularly if they've come across this before.
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May 18th, 2007, 03:14 PM   #2
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theres 02 manuals and stuff in downloads section on here
hope they help
if you need to compare test values or anything mines an 02 as well

give me a shout
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May 19th, 2007, 01:18 AM   #3
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Thanks. I had already downloaded the workshop and user manuals. I've also looked at some of the wiring diags but they do not show the connection for the lights. One of the diag shows the 2nd stator yellow lead not connected to anything as I thing the bikes it's referring to don't have lights fitted.
Maybe the lights should be powered from a 2nd rectifier and regulator using the AC from the 2nd stator lead but I cannot see where this should be fixed. Alternatively I could connect the 2 yellows together and conect in to the existing rectifier and power the lights via the ignition switch from the existing regulator but I don't know if it's man enough.
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May 19th, 2007, 01:57 AM   #4
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Hi loonyberg,

Your lighting system is power by regulated AC only, it one of two things either the regulator is knackered or the earth lead from the regulator to the frame is not good.
There is a mod you can do where your lighting runs direct from the battery but you will require an uprated regulator rectifier.
If you have no increase in voltage across the battery when engine is running sounds like you have a problem there as well should read around 13.8 to 14.5.
Let us know your findings.

Regards

Sparks
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May 19th, 2007, 02:59 AM   #5
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Thanks Sparks. I thought the charging voltage across the battery was too low also as it stays at 12.6V even at 3K-4K revs. I changed the reg 'cos I thought the previous one was knackered but there only seems to be 0.2V difference between the two. Maybe there is a clue there somewhere? Currently the lights are powered from the 2nd yellow stator lead and this seems to be unregulated as the intensity of the lights increases with revs until they burn out. Should there be a regulator in the stator or somewhere else in the wiring in addition to the one for the battery charging circuit?
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May 19th, 2007, 03:49 AM   #6
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OK, your system has two charging output circuits Blue is ground both yellows are common to each other doesn't matter which way round they are .
One Yellow will go to the reulator, the regulator will have a earth wire this is where the unwanted voltage is dumped, from the regulator to the light swich.
The other Yellow goes to the regulator rectifier this also has an earth wire to dump unwanted voltage and from there it goes to the battery. Hope this now makes sense.

Regards

Sparks.
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May 19th, 2007, 04:02 AM   #7
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I think this is starting to make sense. It seems to me that on my bike the regulator rect is connected to the seperate regulator. If I undertsand what your saying, I should connect one of the yell stator leads to the yell flying lead of the seperate reg and then this should also be connected to the feed for the lights. The brown flying lead of the reg being connected to earth. The other reg/rect is connected to charge the battery. Is that right?
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May 19th, 2007, 04:23 AM   #8
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Yes that's about it the regulator is for the lighting and the regulator rectifier is for the battery two seperate units, make sure both units are well grounded and if still no go must be knackered.

Regards

Sparks.
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May 19th, 2007, 04:33 AM   #9
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Ok, I'll change the wiring and do some testing this weekend and report back on the results. Thanks very much for your help.
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May 19th, 2007, 08:34 AM   #10
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Here is the 02 schematic, page 33 of the Owners Manual

Joe
Attached Files
File Type: pdf Page 33 from 2002 Owners Manual.pdf (198.3 KB, 52 views)
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