Lighting/Charging/Perplexing

kneedown · Nov 11, 2004

Here's the deal:

My '99FS600 Supermotard is a fantastic bike for the road & track. However, it doesn't seem to be charging properly. I have it hooked to a Battery Tender constantly when I'm not riding it so it will always pop right off. Then, once it is running, the lights are nice & bright until I blip the throttle--if I rev it they get quite dim (not unlike the owner). The horn & turn signals will not work when I'm riding. The signals will work s l o w l y if I allow it to settle back down to an idle. Normally I would assume that it is a bad stator and order a replacement straight away, but two things prevent me from doing that:

1.) they cost an awful lot.

2.) the engine will always fire strongly off the button, even after riding for an hour or more with very dim lights.

Any ideas?

BundyBear · Nov 11, 2004

Unlikey to be a crook stator. The 12V charging windings almost never give trouble.

Sounds like you possibly have either one shorted diode in your rectifier or somewhere you have one of the stator wires connected to ground. Remember that your regulator has its metal body connected directly to one of the stator wires so if the regulator body is not insulated from the frame it might have the same effect.

I would think it has no effect with the engine running slowly as at low revs the voltage from the stator does not get high enough to get the regulator to go into the short-out (conduction) state. I suspect that when the regulator goes into conduction a LOT of current is going back thru either the shorted diode or shorted stator connection & dragging down the system voltage. Post if you need help checking any of this.

kneedown · Nov 12, 2004

Brad said:
Sounds like you possibly have either one shorted diode in your rectifier or somewhere you have one of the stator wires connected to ground.

Any thoughts on how to diagnose the diode? I'll double check the stator wires using the wiring diagram.

Brad said:
Remember that your regulator has its metal body connected directly to one of the stator wires so if the regulator body is not insulated from the frame it might have the same effect.

Are you talking about the rubber surround that the rect. is held in place with? Everything there is intact & not making contact with the frame. I'll double-check that again, just in case. Or am I thinking of the regulator?

Brad said:
Post if you need help checking any of this.

If you can't tell, I need help. I'm an electrical *****.

dsducati · Nov 12, 2004

I would say Brad is right on looking at the rectifier regulator first. By pass it by hooking the lights directly to the Yellow stator wire. There are 2 of them and each will produce 70 watts. Use each wire one at a time to check them both. Have the bike idling and gently rev the bike and the lights will get brighter. :idea: When they look pretty bright stop revving it or risk popping the bulb. 8O Not sure if the regulator/rectifier having the Aluminum case grounded is a problem or not, but you can always unbolt it and see what happens. May very well be the problem because mine is mounted on the plastic rear fender from the factory.
Dan

kneedown · Nov 12, 2004

I'll check it out DucMan. It may take a bit before I have an answer--very busy weekend coming up.

BundyBear · Nov 14, 2004

Just read a post from tholen. He filled in a lot of detail as to what machines have what electrix.
http://www.husaberg.org/modules.php?nam ... =7502#7502

It seems your '99 model bike should have the rectifier and regulator combined into a single unit that I am not familiar with. If that is so I am not sure if there is any concern having its body connected to ground. It may be that it has to be grounded to work. You mentioned it being in some kind of rubber boot which is different to what I was trying to describe.

My bike and others I have seen with seperate reg and rect units have the regulator bolted to the plastic of the rear mudguard to insulate it from the frame. The rectifier is just next to the top shock mount bolt.

If you have a combined reg/rect unit, does it have either four wires or three wires & a ground connection thru its case? If you want to check its diodes, do you have a multimeter with a diode symbol on it? If not you can use a light bulb connected in series with a battery. If you can describe the wire colours and where they are connected to it should be possible to check the diodes.

tholen · Nov 15, 2004

The 99-00,03 electric started models regulator/rectifier.

3 yellow connections, should be connected to 2 yellow wires (70+70W) and the blue wire from the stator.

Black and red wire from regulator/rectifier are - and + DC,connect it to battery.

BTW,its the same regulator as KTM 620-625 electric started models.
Spare part no. Husa: 180 123-01 KTM:584.11.034.100

kneedown · Nov 18, 2004

Many thanks, gents. I'll check it out this weekend (finally, a day off!) & let you know my findings.

Lighting/Charging/Perplexing

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