Battery failures

FE650E · Aug 20, 2005

Can anyone help with my FE650E. It fries batteries after a short ride. I have replaced the regulator. It does not blow the fuse. I put a new battery in, test the running voltage at around 13.5VDC, but then go for a ride and try start on the electric start and the battery is dead, and does not recover. Any ideas?????? I've put 5 batteries in it now.

BundyBear · Aug 21, 2005

By "fries the battery" do you mean flattens it or blows the side out of it?

Measure the voltage at the battery with the engine running a bit faster than idle. An open-circuit regulator will let the voltage go too high (>17V) & overcharge the battery to the point wher it'll probably rupture.

There are many reasons why a bike might not charge at all (voltage <12V with engine running). Generally a broken or unplugged wire somewhere between the stator, rectifier & battery. Could be a shorted regulator or open circuit rectifier.

faktor · Aug 22, 2005

What year is your Berg
If it is a 2002 or 2000 check the lume under the tank and near steering stem i had a broken wire there repaired it and its all good.

FE650E · Aug 23, 2005

Hi Guys, When I say fries the battery I fit a brand new fully charged battery to the bike. I start and test the voltage at the battery and it is around 13.8 volts. I then take the bike for a ride and within 5 minutes to an hour, the bike will not start on the electric starter, it just clicks. Testing the battery reveals it has gone open circuit. Oddly it will measure 12 volts unloaded, but when a load is put on the battery (ie the starter) the voltage drops to around 2 volts. I have replaced the voltage regulator with no difference. It still damaged the battery. I have fitted 5 batteries to it now. It does not blow the 10 amp fuse in series with the battery recharge circuit, so I am a little stumped as to where a high voltage high current would be coming from to damage the battery. I have not noticed that the battery is actually boiling and distorting the casing, but the failure happens so quickly that I am not certain that excessive current is the culprit. I was thinking it could be a problem with the stator??? Any help would be appreciated.

berger · Aug 23, 2005

Have you tried to recharge any of these batterys? Are you sure they are failed with no chance of recovery?
You may try riding around with your volt meter hooked up so you can monitor the situation.
It sounds like high resistance (corrosion) in your main battery leads may a possibility

husabutt · Aug 23, 2005

What year is your bike?

What battery are you using?

What charger are you using?

Do your lights flicker at low RPM?

BundyBear · Aug 25, 2005

What you describe sounds like the battery (ies) are just flat. 12V at rest indicates a flat battery. You would expect the voltage to drop as soon as you put any load on it in this state. What voltage do you measure across the battery with the bike running at about half revs? Even with a flat battery you should see at least 13.8-14.2V while running. If it is less than this then it is not charging.

BundyBear · Aug 25, 2005

They are definitely putting the acid in the new batteries you have tried?

BrianSM · Oct 25, 2005

12 volts at rest is merely the float voltage (my bike shows that all day)......when checking voltage when the bike is running is just proving the charging system is putting out 13.6 or what ever....does not give any sound proof about the battery.......take a new battery and do a load test on it prior to installing in bike....this will tell you how a battery reacts to a strenuous load and how it bounces back......at least at this point you know whether they are faulty.....all those bad batteries in a row.......really hard to imagine, but If they came in on the same shipment ?????.... It is possible that the wiring is incorrectly installed ???
Is it possible the posts on the batt's are taking a hit and braking them away from the plates inside....Is it possible a inexperienced guy at the batt place is overcharging the battery....they take 6 amps for 30 minutes is considered a fast charge........If the wiring is incorrect you should know pretty quick?????? someone mentioned acid content, bike batt's are shipped and stocked w/o acid as they don't hold a charge for as long as the big ones....I sure hope some of this helps

Battery failures

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