Charging System Diagnosis
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03-09-2008, 11:15 AM
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Charging System Diagnosis
Ok here are some pointers for diagnosing a charging system problem.
#1 check battery voltage. You want 12.6 or higher. But every manual will tell you to have a good battery that is fully charged or the readings will be off. So idealy you would want 13.0 vdc for YTX batteries and 12.8 vdc for YTZ batteries
#2 Start up bike and run it. Anywhere from 3000-5000 rpm you want to check charging system output. You are looking for voltage higher than your battery voltage. Idealy 13.8-14.5 vdc. But readings vary with each bike and their charging system design. A generic rule is higher than battery voltage but less than 16.5 vdc
#3 If your reading was lower than "key off" voltage you disconnect stator leads and check resistance of these wires. You'll have 3 wires...either black, yellow, or white wires. You check your leads a,b b,c and then a,c. You should get about 0.1-1.0 ohms of resistance. Then check each lead's resistance to battery ground. And there should be no resistance. If you have any resistance then you have insulation failing in stator and it needs to be replaced.
#4 Check resistance from stator leads to leads at reg/rec make sure they are less than 1 ohm. Also do the same for the red and green leads from reg/rec to battery post cables. If that is good then you have a bad reg/rec. There is no test for reg/rec it is a solid state component and you test everything else around it eliminating everything and if you have good components and still a problem you replace the one thing you can't test.
Opt step #2 If your charging voltage is like 16.0-18.0 vdc...turn off your bike before you damage something! You have a bad regulator! Overcharging only means one things, bad reg/rec.
Note. If you are running extra lights, high output headlight bulbs even...this can lower your charging output and sometimes draw too much energy and charging system can't put out enough. Your charging system isn't a charging system, it is a battery maintaining system. They run as weak of a system as possible in order to have less load on motor and have more power. So if you are running a low battery and think that your bike will bring it up to full charge...no not really. It'll try but it puts a large strain on the system and can overheat the reg/rec which is one of the main reasons why they go out! And if that goes out sometimes it can take out a stator too! Which that overheats and gets cracks in the insulation. So i hope this helps some people, and eliminates them from having to take it in and they save some money. Any other questions just email. I have more pointers.
#1 check battery voltage. You want 12.6 or higher. But every manual will tell you to have a good battery that is fully charged or the readings will be off. So idealy you would want 13.0 vdc for YTX batteries and 12.8 vdc for YTZ batteries
#2 Start up bike and run it. Anywhere from 3000-5000 rpm you want to check charging system output. You are looking for voltage higher than your battery voltage. Idealy 13.8-14.5 vdc. But readings vary with each bike and their charging system design. A generic rule is higher than battery voltage but less than 16.5 vdc
#3 If your reading was lower than "key off" voltage you disconnect stator leads and check resistance of these wires. You'll have 3 wires...either black, yellow, or white wires. You check your leads a,b b,c and then a,c. You should get about 0.1-1.0 ohms of resistance. Then check each lead's resistance to battery ground. And there should be no resistance. If you have any resistance then you have insulation failing in stator and it needs to be replaced.
#4 Check resistance from stator leads to leads at reg/rec make sure they are less than 1 ohm. Also do the same for the red and green leads from reg/rec to battery post cables. If that is good then you have a bad reg/rec. There is no test for reg/rec it is a solid state component and you test everything else around it eliminating everything and if you have good components and still a problem you replace the one thing you can't test.
Opt step #2 If your charging voltage is like 16.0-18.0 vdc...turn off your bike before you damage something! You have a bad regulator! Overcharging only means one things, bad reg/rec.
Note. If you are running extra lights, high output headlight bulbs even...this can lower your charging output and sometimes draw too much energy and charging system can't put out enough. Your charging system isn't a charging system, it is a battery maintaining system. They run as weak of a system as possible in order to have less load on motor and have more power. So if you are running a low battery and think that your bike will bring it up to full charge...no not really. It'll try but it puts a large strain on the system and can overheat the reg/rec which is one of the main reasons why they go out! And if that goes out sometimes it can take out a stator too! Which that overheats and gets cracks in the insulation. So i hope this helps some people, and eliminates them from having to take it in and they save some money. Any other questions just email. I have more pointers.
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