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Battery Charging Problems

Joined Jun 2001
102 Posts | 0+
Melbourne Australia
My 03-FE501E doesnt seem to be charging the battery.

I have 12.6v at the battery when not running, and basically same volyage when started and reving. ie no detectable voltage change.

Both yellows of the stator read from 10-50+ V AC the higher the revs the higher the voltage.

The red white wire off the Rectfier/Regulator reads from 5-8 volts DC, and 10-16 V AC. (higher readings with higher revs) I thought this should have only read as a DC Voltage of approx 13.5V.

I bought a new Rectfier/regulator and the new one gives the same results.
I ran a new earth wire into the rectifier with no change.

The Red wire that comes from the regulator tops reads from 10-12.4 VAC.


Resistance reading across the stator seem ok
Red/Black 2.7kohms
green/black 164 ohm
yellow/blue <1 ohms

Anyone got any ideas as to whats going on? Advice appreacitaed

Cheers
Horto
 
Begin to start the engine, lights on. See if the lights increase when you open the throttle. If they do, your charging system is OK.
With a multimeter, switch to V AC put the probes on the battery terminals, red on + black on -. With the engine running if you open the throttle the meter should move to 13,... Vs. If all this works, your charging system is OK.

Check your wiring. Sometimes due to the poor wiring quality, the wires broke somewhere, most of the times on the steering column. Check all the connections and good luck. :wink:
 
50V AC is pretty normal for yellow wires coming from a stator at moderate revs. Red wire that goes to the battery should be around 14 volts. Be certain wiring connections are good and black/wh wire is grounded. Don't mention if E Start works, but if fuse at selenoid blows, will lose E start and charging system.
dan
 
Thanks guys

Bike starts almost instantly on starter hot or cold. Lights work fine, its only voltage at the battery and coming out of the rectifier-regulator that appears incorrect. I have already replaced the rectifier once but it still only outputs 5-10v dc from the red-white wire/pin. This is same whether wire connected or I just measure directly on the pin directly on the regulator.

Will try running a new wire directly from this pin down onto battery and see if this changes anything.

Cheers
Horto
 
Problem solved. Thanks to all those that offered advise.

After leaving it for a few days I realised it had to be a broken wire (thanks Husby) Even if its wasn't charging I should have been reading the voltage of the battery as a minimum on the read white wire at the Rectifier. Given this was reading 8 to 10 volts when battery was 12.7v wire must have been broken. I attached a new wire from rectifier and attached it to battery stared her up and instantly had 13-14.4 volts depending on revs.

Cut loom open and found it was up near headstem where red/withe wire from rectifier joins up with 4 other red white wires. Solder up a new wire/connection and jobs done.

Whilst I was at it I wired in a new 12v power plug/cigarette lighter, the previous one I had was one I bought from the automotive accessories shop, but it constantly filled with mud and slowly corroded, so I relaced it with one from a boat shop. It is stainless steel inner and plastic outer with a cap to seal opening when not in use. Only cost $7.5 aus. I use this to power GPS which otherwise consumes a couple of sets of battery on a good ride.

Cheers
Horto
 
I posted the fix in the wire headstem for lefrog about 3 weeks ago now. Seems to be a common problem.
 

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