'04 FE450 not charging

ben_moto501 · Nov 3, 2011

Hi everyone!
After looking at my bike more in depth I have come to the conclusion the battery isn't getting charged when the bike is running! I have charged the battery fully and now with a multimeter it reads 12.8v. When I start the bike it reads the same and also the same while revving the bike! Would this point towards the stator or maybe the regulator/rectifier? I have an old regulator/rectifier from an '03 bike (SEM ignition) would this fit onto my '04 bike with the newer ignition?
Otherwise what should I be looking at?
Can someone tell me how to check the stator and on which settings on my multimeter?

Many thanks!!

Ben

ben_moto501 · Nov 3, 2011

Also another point is that on Ebay the stators advertised seem to have loads of wires coming out of them! The one on my bike only seems to have 4!! Is this correct and has my bike (I've only owned it for a few months) ever been charging? I always keep it on a battery tender when I'm not using it!

Thanks in advance!

Ben

sparks · Nov 4, 2011

Hi Ben,

To start with just drop off the ignition cover and check the soldered earth tab is still well soldered, in this year these had a tendency to become dry jointed.
If that ok and the windings look in good health do a AC voltage check across Yellow and White, then in turn each one to earth.
There isn't any voltage values to go by but you will know if there is a problem by a low output. Out of all the coils on the stator only one of them is for charging the battery, across Yellow and White, the others for the lights.

Do your lights work?, also check the connector plug of the reg/rec and the wiring to the fuse and battery.

Regards

Sparks.

ben_moto501 · Nov 4, 2011

Yes my lights work and when the battery is charged everything works as it should! I heard about the dry joint thing before so I've checked that and they all look good! When you say check across the windings to earth is this with the bike running or not?
Is the regulator/rectifier under the seat or hiding else where?

If it does turn out to be the stator I hear yours (Sparks) are the best... Would you supply me with one and what's the asking price for this?
Thanks for the reply mate! I'll check the voltages and post up the results!

Ben

sparks · Nov 5, 2011

Hi Ben,

With the engine running at a steady rpm, just check across the wires to see what AC voltage is coming out.

From memory I think it is White and Yellow for charging and Yellow to Earth for the lights.

The Reg/Rec is under the tank, with a 4 wire block connector.

If you have good AC voltage check to see if one of the four wires at the Reg/Rec is showing battery voltage,with the engine turned off, if yes it's the Reg/Rec if not you have a broken connection some where.

Regards

Sparks.

ben_moto501 · Nov 8, 2011

Well I haven't had chance to check the voltage readings from my stator yet but I did have time to wiggle all the connectors and spray all the electrics with WD40! I quickly checked the output accross the battery with it running and now it seems to be around 13.3 volts and when I rev it it goes up to 14.4 volts! I think I've sorted it!

Sparks out of curiousity as I'm sure the stator will die one day, can you 'pm' me a price on one of your lovely stators with postage to the UK please? I might take one off your hands or at least know where to come when it does die!

Thanks!

Ben

sparks · Nov 9, 2011

Hi Ben,

Well it looks like you on to a winner there, bad connection somewhere. Regarding your ignition side, well when they moved to this ignition in 2004 the only real problem was that earth joint desoldering I mentioned, the actual output source coils are very reliable and never really had cause to rewind one that failed due to electrical failure, done a few where people have a screw driver in the wrong place but that's about it.

Because this system runs on a lot lower voltage than the SEM you don't get plagued with the same problems, in fact this rings true with all Jap ignitions that use a lower source voltage.

But having said that hope I haven't put a curse on yours.

Regards

Sparks.

ben_moto501 · Nov 9, 2011

Ah I see! Thanks for your help mate! Will try to keep the screw drivers at a safe distance!
As soon as I get a chance I'll still do a voltage check like you described as then I'll have an idea what it should be while it's working!

Thanks again!

Ben

sparks · Nov 10, 2011

Hi Ben,

If it is pushing 14.4 14.8 just off idle then it's ok, just do a check on all your connectors, this will of been your problem.

Regards

Sparks.

ned37 · Nov 10, 2011

fwiw, my old '04 450 was wired so that the headlight ran off dc. had a 50w halogen lamp. could not run with the light on for more than an hour or the bat would go dead. system wasn't quite strong enough to do it. changed lite to ac and all was well.

'04 FE450 not charging

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