Big Electrical Problems Need Suggestions

[jamestoo]

Hi

Can Anyone please help with my electrics on my BD Quick release duelsport kit i've recently uprated my headlight bulb to 55w then rewound my stator which is where my problems started The extra power coming from my stator burned out the regulator/rectifyer this I replaced and now I have no electrics whatso ever with the bike stopped or started!

The battery is fully charged up and showing 13.8V +

The Voltage from the stator is 25V + AC measured under the seat and at the two yellow wires coming to the headstock.

The voltage coming out of the new regulator/rectifyer into the battery is ~5V DC

There is nothing working at all with the bike running or stopped. ?

I am now wondering if it could be the swich on the handel bars

Any help or suggestions would be greatly appreciated

[SniperTeamBravo]

Hi

Can Anyone please help with my electrics on my BD Quick release duelsport kit i've recently uprated my headlight bulb to 55w then rewound my stator which is where my problems started The extra power coming from my stator burned out the regulator/rectifyer this I replaced and now I have no electrics whatso ever with the bike stopped or started!

The battery is fully charged up and showing 13.8V +

The Voltage from the stator is 25V + AC measured under the seat and at the two yellow wires coming to the headstock.

The voltage coming out of the new regulator/rectifyer into the battery is ~5V DC

There is nothing working at all with the bike running or stopped. ?

I am now wondering if it could be the swich on the handel bars

Any help or suggestions would be greatly appreciated

One thing you needed, ye=s I said needed to know about the new stator was that when hooking it up as a single output mode wll fry a BD reg/rec! Oh well, buy a new reg/rec, and use one side of the stators output to it, the other output goes to a STOCK AC regulator, then usually directly to the headlight. The AC side runs the headlight only, the side wired to the Rec/Reg runs everything else. I have a stock stator, but am upgrading to a Ricky statror 200w and going to run it like I stated. I got all this info from research done on this topic because I want more light output, and the stock stator on my XR sucks ass....

Your problem sounds like a ground. The BD rec/reg needs to be grounded directly to the frame, don;'t use the black wire into it to ground the battery, it will not work on some bikes. Try grounding the battery ground directly to the frame insteqad of to the rec/reg....when the bike is running, you should get about 13.8vdc at the battery or a little higher....good luck mate!

[jamestoo]

Thanks

I'll check the earth any other suggestions greatly recieved!

[SniperTeamBravo]

Thanks

I'll check the earth any other suggestions greatly recieved!

Actually I left something out of my previous post, the BD rec/reg also needs to have the ground hooked to uh ground! The battery should also be grounded but not to the rec/reg, ground the battery to one of the points close to it on the frame. You should have the rec/reg and an AC regulator both hooked up to one of each of the two outputs off of the stator. Now a question, did you have it rewopund in dual output mode? If not you have problems...let me know.

[jamestoo]

i rewound the stator myself but the problems occured when i went for a night ride and the 55w uprated bulb ran the battery dead in minutes leaving me in darkness on the road

It then seemed like the reg/rectifyer was fried as the DC output to the battery was zero

I then bought a replacement motorbike reg / rectifyer from ebay I think this is now the problem it has two yellow inputs (AC from the stator) and a black and red DC to the battery (the original BD reg/rec has a blue wire also cant remember now where that connected)

The stator is pushing out ~25V AC at the two yellow wires at tickover that go into the reg/rec (I presume this is rewound and connected ok)

The output on the DC (battery) side is ~5V

I've now got to the point where i've wires all over the place and I wish i'd just bought a rewound stator off the shelf ?

I really havnt got a clue so i'm tempted to call BD and buy another uprated reg/rec and rewound stator and probably now a switch unit also so i know i'm then back to square one

I'm so pissed with it now a KTM is looking very attractive

[SniperTeamBravo]

What bike is it? XR650 or XR600R? Anywho, let me check my notes and find out what the resistance should be on the wires from the stator...ill get back to you.

[SniperTeamBravo]

OK, check the outputs of the styator without the bike running, ptu it on resistance or Ohms, you shoulc get 1.0 ohms resistance +- .010 ohms. Also you should see 12vac from EACH side of the individual outputs, or 24~25VAC from the two sumed outputs. I would run it in the dual output mode so one 12vac out to the av regulator, headlight and the other to the rec/DC reg to the other accessories....

[jamestoo]

Sorry Should have stated the bike its an 02 XR650R

I really appreciate your trouble!

OK Checked the resistance at the two yellow wires at the headstock coming from the stator i get 0.9 Ohms

Cant start it at the mo as kids in bed etc! ? so i'll check the individual ac flow on the yellow wires in the morning

[SniperTeamBravo]

0.9 OHMs is perfect....good then, lets noodle on it from there. Ill talk to ya tomorrow. Id say it is the ground. Ill find some links and get back....

[jamestoo]

Ok i've started the bike and done a seperate AC voltage check on each of the two yellow wires coming from the stator at the head stock the AC voltage on each wire just over tick over is ~13V - 15V AC ?

I have now also done this to test:

I have connected the yellow wire (AC) direct from the stator to the blue power wire leading to the handel bar switch (this now goes directly from 1 stator output to the handelbar switch no reg/rec) when i start the bike i've got voltage at the switch but no power back to the lights

i'm thinking the handel bar switch is now broken

[SniperTeamBravo]

OK then, go here and see your handelbar switch and click on it. then go thru the instructions to see if all is hooked up right, but watch out for the stator, only hook up one of the outputs for now to the rec/reg so we can get this thing working and tackle the second output thing afterwords.

http://www.bajadesigns.com/2005%20Web%20Site/manualsmain.htm

[jamestoo]

Ok Checked through everything still no joy I've come to the conclusion that the switch is now F*&%ed so i've ordered another replacement switch so i'll try that as soon as it arrives

Thanks very much for all your help so far

james

[SniperTeamBravo]

Ok Checked through everything still no joy I've come to the conclusion that the switch is now F*&%ed so i've ordered another replacement switch so i'll try that as soon as it arrives

Thanks very much for all your help so far

james

Sure thing, let me know when the switch arrives and what the outcome is. Good luck!

Oh, after i thought about it, have you allready re-plugged all the connections in tight? If not do so after or before the switch gets there. It is a good thing to do. My XR600R had a problem for a day with the turnsignals not flashing or flashing intermittently. New Flasher, basically new turn signals too. But had always worked great. I started un-plugging the connections and re-plugging them to see if anything was loose, when I got to the flasher it was full of friggin water! Changed it to a new one, no more problems!

As we seek a problem in a certain sequence, we find other answers....an old Sniper X proverb!