Contact Overland Solutions for all your custom modifications and setup for overland travel.               Discover the extraordinary with Compass Expeditions.

Go Back   The HUBB > Technical, Bike forums > Yamaha Tech
XT charging issue XT charging issue
Register FAQ Calendar Search Today's Posts Mark Forums Read

Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
With more than 58 destinations worldwide, Edelweiss Bike Travel is Number 1 in guided motorcycle tours!
Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 19 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
XT charging issue
HI,


My XT600e doesn't appear to be charging but I cant figure out why.
  • I have done a continuity test on all of the charging system wiring and it's all fine.
  • I have checked the resistance on the alternator and again it's within spec.
  • I was getting no voltage output from the regulator rectifier so I replaced it with another one from a TZR 250 same unit but different part number.
  • I tested the unit and it was putting out about 14 volts at 3-4000 revs so I thought OK were in business.
  • I put the battery on charge and tonight It started fine.
  • a ran about 10 miles with lights on and then parked up and when I came back it started no problem.
  • I then did a another 10 miles with the lights on but when I got home the battery didn't have enough to start.
  • Repeated all of the above tests and they all check out.
Now the battery was replaced about 7 months ago so I really don't understand.

Any ideas?
Reply With Quote
  #2  
Old 19 May 2009
wolfzero's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Location: uk
Posts: 432
the battery may be faulty as you have had the bike stripped for repairs/restoration and if its not been charged and discharged it will sulfate reducing its life and capacity, if the reg rec was faulty it may have damaged the battery by overcharing before it went caput.
__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
  #3  
Old 20 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
Thanks for the reply. I reckon your right, the process of typing out my post led me to go out to the garage and test the battery and it's definitely not holding a charge. I also closely inspected the the faulty reg/rec and found some extreme heat damage (melting) around the output spade.

So I'm guessing a faulty regulator shunt had been boiling the battery.


New battery then.......ho hum.
Reply With Quote
  #4  
Old 22 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
Well now I'm stumped new battery went in this morning and was fully charged ran the bike to work and back no probs.

Ran the bike over to a friends tonight with the lights on doing a steady 75 all the way about 25 miles and when I stopped to get fuel .....you guessed it flat battery.

even tried a spare reg/rec from one of my GSX 1100s tonight ( same set up three phases in from the alternator and one out back to the battery) but no joy.


What have I missed, any suggestions?
Reply With Quote
  #5  
Old 22 May 2009
wolfzero's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Location: uk
Posts: 432
earth leads?. have you painted the frame recently and if so did you make sure the regrec was properly earthed.
i had my frame powder coated so had to grind the coating off on all the earth points inc under the reg.
__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
  #6  
Old 22 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
Thanks for the reply but I'm beginning to think the original fault may have damaged some of the windings in the alternator. When I fist went looking for the fault I did find a damaged section of insulation on one of the phases from the alternator up near the reg rec where it had been rubbing on the frame. I replaced the section soldered it and shrink wrapped and thought no more about it.

I'm now beginning to think this might have been the original fault that has so far toasted the battery , the regulator rectifier and now it would seam that its scored the a full house on the charging system by damaging the alternator.


I'll get the generator cover off tomorrow and take a proper look.

I'll let you know how It goes.
Reply With Quote
  #7  
Old 23 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
Well after testing the generator under load using a megger there were no signs of trouble. I concluded that leaves only the rather tatty loom.

So I bypassed it completely by relocating a spare GSX1100 reg/rec were the tool kit normally sits. I made up a new loom to connect to the output from the alternator and earthed directly to the battery earth. I put the output from the reg/rec back to thee original red wire in the loom ( now considerably shorter so that it came out of the loom just above the battery.

Here's a pic of the the initial diagnostic set up ( will it work set up)
As you may notice I also extended the leads on my multimeter and wired them into the battery terminals so that I could monitor the charging activity under various conditions.
Reply With Quote
  #8  
Old 23 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
This is my simple but effective attempt to understand what the charging system was doing under load.

What I found was I was getting 14.9 volts while riding and that dropped down to 14.8 when the lights were on.

so it looks like it was the loom at fault the wiring in the rear section gave a result on continuity but when a stripped the insulation back the wire was as black as the earl of hells waistcoat and was probably creating too much resistance under load.

So do these charging voltages sound good or do you think they should be lower?

Reply With Quote
  #9  
Old 23 May 2009
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 772
Sounds spot on.
Reply With Quote
  #10  
Old 23 May 2009
wolfzero's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Location: uk
Posts: 432
i think that it kinda confirms my previous thoughts on poor earths have you tried running a direct battery neg lead to the reg on the original set up.

14.8v sounds a little high especially with the lights on but digital gauges are very sensitive so might not be an issue.
__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
  #11  
Old 23 May 2009
Registered Users
New on the HUBB
  
Join Date: Oct 2008
Posts: 10
Thanks, yes when I'm allowed back out to the garage again that's exactly what I'm going to do.
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes
Linear Mode Linear Mode

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
charging! mountainboy65 Photo Forum 5 15 Apr 2008 00:38
charging a phone yorkiedave Equipping the Bike - what's the best gear? 11 8 May 2006 00:44
Charging batteries Forsellini South America 6 19 Jan 2006 20:09
2nd battery charging longroadtrip 4WD Overland Tech 17 15 Aug 2005 22:34
93 XT charging problems IanW Yamaha Tech 1 10 Mar 2002 19:19


All times are GMT +1. The time now is 21:06.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top