Lights burning out on 2002 FS650e

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L

loonyberg

Joined
May 7, 2007
Messages
96
Location
Cambridgeshire, UK:2002 FS650e
When I increase revs on the engine with lights on, they glow brighter with increasing revs until they burn out. I contacted DCR in UK and they suggested I modify wiring,
Stator blue lead connected to earth spade around regulator mounting bolt
Stator yellow(1) to yellow connector on rectifier
Stator yellow (2) to red lead in wiring loom
Regulator brown lead to earth
Regulator yellow lead to yell/brown connector of rectifier
Note this model has separate reg and rectifier.

Have done this mod but lights still blow. If I had a wiring diag I can follow it but DCR said no diags for 2002 are available. Should lights be connected to regulator or to battery? Battery seems to stay at 12.6V irrespective of revs.
Can anyone suggest something I can try, particularly if they've come across this before.
 
theres 02 manuals and stuff in downloads section on here
hope they help
if you need to compare test values or anything mines an 02 as well

give me a shout
 
Thanks. I had already downloaded the workshop and user manuals. I've also looked at some of the wiring diags but they do not show the connection for the lights. One of the diag shows the 2nd stator yellow lead not connected to anything as I thing the bikes it's referring to don't have lights fitted.
Maybe the lights should be powered from a 2nd rectifier and regulator using the AC from the 2nd stator lead but I cannot see where this should be fixed. Alternatively I could connect the 2 yellows together and conect in to the existing rectifier and power the lights via the ignition switch from the existing regulator but I don't know if it's man enough.
 
Hi loonyberg,

Your lighting system is power by regulated AC only, it one of two things either the regulator is knackered or the earth lead from the regulator to the frame is not good.
There is a mod you can do where your lighting runs direct from the battery but you will require an uprated regulator rectifier.
If you have no increase in voltage across the battery when engine is running sounds like you have a problem there as well should read around 13.8 to 14.5.
Let us know your findings.

Regards

Sparks
 
Thanks Sparks. I thought the charging voltage across the battery was too low also as it stays at 12.6V even at 3K-4K revs. I changed the reg 'cos I thought the previous one was knackered but there only seems to be 0.2V difference between the two. Maybe there is a clue there somewhere? Currently the lights are powered from the 2nd yellow stator lead and this seems to be unregulated as the intensity of the lights increases with revs until they burn out. Should there be a regulator in the stator or somewhere else in the wiring in addition to the one for the battery charging circuit?
 
OK, your system has two charging output circuits Blue is ground both yellows are common to each other doesn't matter which way round they are .
One Yellow will go to the reulator, the regulator will have a earth wire this is where the unwanted voltage is dumped, from the regulator to the light swich.
The other Yellow goes to the regulator rectifier this also has an earth wire to dump unwanted voltage and from there it goes to the battery. Hope this now makes sense.

Regards

Sparks.
 
I think this is starting to make sense. It seems to me that on my bike the regulator rect is connected to the seperate regulator. If I undertsand what your saying, I should connect one of the yell stator leads to the yell flying lead of the seperate reg and then this should also be connected to the feed for the lights. The brown flying lead of the reg being connected to earth. The other reg/rect is connected to charge the battery. Is that right?
 
Yes that's about it the regulator is for the lighting and the regulator rectifier is for the battery two seperate units, make sure both units are well grounded and if still no go must be knackered.

Regards

Sparks.
 
Ok, I'll change the wiring and do some testing this weekend and report back on the results. Thanks very much for your help.
 
Here is the 02 schematic, page 33 of the Owners Manual

Joe
 

Attachments

  • Page 33 from 2002 Owners Manual.pdf
    198.3 KB
I've now redone the wiring to return it as it should be, particularly around the voltage regulators. Battery now charging to around 13.8V - 14V and lights now regulated irrespective of engine revs so no more bulbs blowing It's now off to Jim Aim to book an MOT then I should be on the road in June. Can't wait!!! It should be interesting as Jim Aim is a KTM dealer who used to do Husaberg I understand.
Thanks to everyone for their help and advice in sorting out this problem. This is a great site for owners of these bikes to discuss problems and receive/give advice from all parts of the world. :turn-l:
 
Hi Loonyberg,

Alls well that ends well glad to here the problem is now sorted, when you go to Jim Aims pass my regards on to Jason, say Steve says hello from Bradford ignitions, I used to do a lot of work for them when I was in the UK especially Motoplats.

Regards

Sparks.
 
Sparks, They say hello at Jim Aims. Bike passed okay and am now out on the road. This 650 is a monster as it seems from the engine note that it's not going fast then I look at the speedo....!
 
Good news Loonyberg, yes they don't hang about once you get them wound up.
But alass mine is still in bits gearbox problems kept jumping in and out of third gear.
After stripping the gears off the counter shaft somebody had rebuilt it in the past and put one of the stop disc at the wrong side of the circlip, so just a new set of bearings and a cam chain should be like new again.

Regards

Sparks.
 

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