charging problem

dirtworker · Dec 24, 2008

:? help!!! I have a 98 fx600 that has never charged the battery.I charge the battery each ride.changed the regulator and rectifier. checked voltage between yellows and ground - 8 vac at idle 30 vac reved up.7 -16 vac between blue and ground. 3-13 vac between blue and yellow. not sure what it should be. have 8-30 vdc at rectifier until load is applied, then zero. any help would be great. thanks.

oyk · Dec 25, 2008

hi, go to the downloads section and find 98 fee electrical diagram.

surely something is wrong with your wiring.

supertireguy · Dec 25, 2008

Those multimeter readings are good to know but we also need to know what readings you measure at the battery when the bike is running at low-mid rpms.

Stator/Rotor output numbers are typically in the 40-60v AC range. This A/C power is routed thru the reg/rect which then normally outputs 14.4v DC for consumption by the bike, lights, etc.

14.4v DC is the target charging voltage number when the bike is running for happy battery charging.

ned37 · Dec 25, 2008

sounds like your rectifier is a rectifryer.
whats confusing is that blue IS ground and you're saying you have 7-16v between the two. if you disconnect blue from ground, you're grounding thru the meter and depending on the impedance of the meter, that's not a good thing. like stguy says, measure what's actually going in the battery on the dc setting.
also, just as an exercise, disconnect and CLEAN all grounds. i believe your model has a separate regulator and rectifier that are mounted thru the case. i know the screw on the regulator needs to be a good ground. i'm not 100% sure about the mount on the rectumfrier. i'll see if i have a schematic on that model as i don't think it was in the downloads.

ned37 · Dec 26, 2008

i found my 98 schematics, but since they got wet back in 98, the pages are kinda stuck together above the "desert model usa" page. #-o
but the non-us elduro doesn't show a ground on either reg or rect and that's not right

dirtworker · Dec 26, 2008

I have schematic from my manual - everything checks out. wiring is stock - never been cut on. rectifier has a ground wire and case is grounded to frame. regulator mounted to plastic mud guard. checked for broken wires ect. still stumped!

DaleEO · Dec 26, 2008

As Sherlock Holmes father said:

"When everything that is probable has been eliminated, then whatever remains, however improbable, has to be the answer".

It would appear based on your readings, and your assurances that everything is intact and well grounded that your charging coils are bad. However, I would consult the oracle, Sparks on this one. Shoot him a pm and he will get you straightened out I'm sure.

sparks · Dec 27, 2008

dirtworker said:
:? help!!! I have a 98 fx600 that has never charged the battery.I charge the battery each ride.changed the regulator and rectifier. checked voltage between yellows and ground - 8 vac at idle 30 vac reved up.7 -16 vac between blue and ground. 3-13 vac between blue and yellow. not sure what it should be. have 8-30 vdc at rectifier until load is applied, then zero. any help would be great. thanks.

Something a bit strange going on here, firstly I have never seen a SEM with a defective Alternator output.
With the two Yellows and Blue disconnected Check the AC voltage from Blue to each Yellow should peak at around 60 to 70 volts. There should be no readings between Blue and ground or just across the two Yellows.
If this tests good then there is a problem either with the wiring or connections or defective Regulator or Regulator Rectifier.
Do your lights work Ok, if fitted they run AC from the Regulator?.

Regards

Sparks.

sparks · Dec 27, 2008

dirtworker said:
:? help!!! I have a 98 fx600 that has never charged the battery.I charge the battery each ride.changed the regulator and rectifier. checked voltage between yellows and ground - 8 vac at idle 30 vac reved up.7 -16 vac between blue and ground. 3-13 vac between blue and yellow. not sure what it should be. have 8-30 vdc at rectifier until load is applied, then zero. any help would be great. thanks.

Something a bit strange going on here, firstly I have never seen a SEM with a defective Alternator output.
With the two Yellows and Blue disconnected Check the AC voltage from Blue to each Yellow should peak at around 60 to 70 volts. There should be no readings between Blue and ground or just across the two Yellows.
If this tests good then there is a problem either with the wiring or connections or defective Regulator or Regulator Rectifier.
Do your lights work Ok, if fitted they run AC from the Regulator?.

Regards

Sparks.

dirtworker · Dec 27, 2008

RE: Re: charging problem

thanks sparks, Ithink you solved my mystery! I have 13 vac between each yellow and blue. 3 vac between the yellows. 18vac between blue and ground. I have no lights on bike, thats what i'm trying to get. I hooked a light directly to each yellow and the voltage went to zero. Go figure I get the only one in the world thats bad! Thats my luck! what is the approximate cost to get it re wound?

Thanks again,

Dirtworker

ned37 · Dec 27, 2008

RE: Re: charging problem

i had a stator on one of my 98 models that had no ac output off the yellows. but it was zero, not a low voltage. try taking your voltage reading as close to the stator as possible to rule out a bad wire or a pinch shorting the blue and yellow at the clamp.

dirtworker · Dec 27, 2008

RE: Re: charging problem

upon further checks with my wwII vintage analog meter , the readings were zero.As soon as I can get a puller, I will check things out further.

thanks for all the help!

dirtworker

sparks · Dec 28, 2008

Re: RE: Re: charging problem

dirtworker said:
thanks sparks, Ithink you solved my mystery! I have 13 vac between each yellow and blue. 3 vac between the yellows. 18vac between blue and ground. I have no lights on bike, thats what i'm trying to get. I hooked a light directly to each yellow and the voltage went to zero. Go figure I get the only one in the world thats bad! Thats my luck! what is the approximate cost to get it re wound?

Thanks again,

Dirtworker

If there is a problem with the windings then it wouldn't be cost effective for me to rewind the Alternator coils, there is enough time alone just doing the ignition windings. But I can do you a stator with rewound ignition coils and a good set of Alternator windings.
But if this is the case you will the first person I have come across that has failed Alternator windings.
What part of the world do you live?.

Regards

Sparks.

sparks · Dec 28, 2008

Re: RE: Re: charging problem

dirtworker said:
thanks sparks, Ithink you solved my mystery! I have 13 vac between each yellow and blue. 3 vac between the yellows. 18vac between blue and ground. I have no lights on bike, thats what i'm trying to get. I hooked a light directly to each yellow and the voltage went to zero. Go figure I get the only one in the world thats bad! Thats my luck! what is the approximate cost to get it re wound?

Thanks again,

Dirtworker

If there is a problem with the windings then it wouldn't be cost effective for me to rewind the Alternator coils, there is enough time alone just doing the ignition windings. But I can do you a stator with rewound ignition coils and a good set of Alternator windings.
But if this is the case you will the first person I have come across that has failed Alternator windings.
What part of the world do you live?.

Regards

Sparks.

dirtworker · Dec 28, 2008

RE: Re: RE: Re: charging problem

sparks- thanks for the info.when I get a flywheel puller I will check things further. I live in california- near sacramento.

dirtworker

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