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FE650 Battery issue

Joined Feb 2012
81 Posts | 2+
Townsville Australia
Hey guys, just got my 650 engine back together yesterday and it was running like a champ, was a hot day and the fan was running alot of the time, I stopped one time during the middle of the ride and from then on I had lost the battery, the bike still kickstarted fine and all the electricals work when the bikes on (aside from the fan, it boiled over once as a result). I thought it might get enough charge by the end of the road, but there was no sign of it even thinking about turning the starter. I put a multimeter on it tonight and was only getting 6v, checked all the wiring thinking I had missed a plug and everythings connected (I even contact cleaned and filled all the plugs with di-electric grease) the bike was also only pulled down last month so it wasn't apart long.

I would be thinking it was the battery but is its only a couple of months old (lithium battery) the stators obviously working when the bikes running. Is it likely a battery issue or possibly the regulator rectifier? I've got it on charge tonight.
 
Quick test,

With your engine running you should be getting 13-14 volts at the battery, if you are the battery is the issue, if not then look at the charging system.

Good luck.
 
Hi 08FE650,
with the bike running what is the voltage at the battery terminals with the battery connected and then the battery disconnected ? This might tell you if its a battery fault if the voltage is much lower when the battery is connected may indicate a problem with the battery.
If you suspect a battery problem, charge it and measure the voltage and leave the battery for 24 or 48 hours and retest it. If the battery is shot the voltage should be down.
If you have just dropped the motor back into the frame is it possible that on the reconnect you touched the frame with a +ve wire and blew a fuse. That would also explain bike running once kick started, fan not running at all and absolutely nothing at the starter. If starter or fan make any noises at all when the start button is pushed or when the fan switch is tripped then it not the fuse if its completely dead quiet then it could be a fuse.

Hope that's of some help
Anthonys4691
 
Try pushing in wires on plug on starter fused relay the come apart from pulling the apart also the plugs next to fan fuse the can short on frame and are very hard to see they are damaged and last charge you battery with a trickle charger not a fast car one they stuff the battery up very quickly. Good luck.
 
There were no shorts, but it seems it's the battery I had it on charge overnight turned it on this morning and only got 12v at the battery while running. The bike died because I forgot to open the fuel taps back up after having the tank off and the battery didn't have enough charge to start it again, it was down to 10v. I'm thinking perhaps the fan running completely killed the battery and it just won't come back from the dead, seems pointless checking the stator if the charger can't do it. Hoping the heap of **** has warranty.
 
It's also a car charger, but I had it on the 1a setting. It cuts out as soon as the batterys full. It has a rejuvination setting that requires it to be on the battery for 24hrs but I doubt it will work on a lithium.
 
1amp should be ok i have found a 900ma its slow but the only one that doesn't stuff the batteries up over time.
 
With the engine running you should be getting more than 12volts at the battery, so with the fan running the battery has hit rock bottom as it isn't being charged by the bikes generator.
Check your connections to and from the reg/rectifier.

Good luck with the battery refund. :(

Carl
 
Thinking more the regulator rectifier now, after that last post I put it on for a quick charge (figured id get one start out of it) and went for a ride, battery seemed to last most of the ride but the fan never came on (bike boiled over at one point) going to go over it properly with the multi meter after work, **** I hate electrical gremlins.
 
So this saga has continued. My battery ended up with a dropped cell (its lithium) and the bike would not start with it connected. I ended up heading to the bike shop today to get one under warranty and they are a bit suss as I had ordered a regulator which I don't think I need and gave me one to test (I do think though that a lithium should be able to handle a few cycles of going flat, only did it maybe 4 times). Anyway, new battery in started the bike and I'm still not getting correct voltage.

Everything in the owners doc talks about a blue wire coming off the stator. I have only a yellow and white that don't go to the CDI and I'm only getting 3vAC, does this mean my stators ******??
 
pull the cover and look closely at the wire connections to the stator. excessive amp pulling can sometimes overcook the solder joints.
 
Just pulled the stator, theres some minor cracking in the varnish and some of the solder joints didn't look the best. I resoldered and went up to 4.something volts. I guess the stators toast though.
 
Do you know someone with another Berg you can swap it over with just to double check?
 
Yeah I do, but went in to the bike shop with it today seems likely its the cause. I mean theres only 3 things in the charging system really, so I've got a new battery and a new stator should be here next week. They credited the regulator I had ordered to it for me but arent going to send it back until I put the stator in next week LOL. I figure though the reg can't do anything without voltage going to it. Just never looked at the stator because the bike ran and the lights worked
 

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