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Post by dickyh on Oct 7, 2015 5:58:55 GMT -5
For some time I have been plagued with battery charging issues. I have an 11pole ac stator (new) 6 pin regulator (new). Both replaced about a month ago and all was fine. I put on a new stator as I thought this might be the stem issue as regulators are only a temp fix. Now once again, I have battery charging issues. output to the battery barely reaches 12V when idle and never gets up to 13+ at higher RPMS Is there another electrical part that could be the culprit? Scoot starts fine when the battery is charged, but after 7 mile ride to work, battery is at about 11 volts (newer battery as well) This has been a recurring issue for that last 4 or so months. New regulator = charging for a couple of months and then  Any comments suggestions? |
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Post by lain on Oct 7, 2015 6:58:21 GMT -5
The wires, have you checked the wires? I know from experience they can visually look good but on the inside of the insulation be all fried and beaten up. Find a nice quiet time of the day, or a quiet room, and try and move the wires around in your hands. If you hear crinkling sort of like a very small or tiny plastic bag contained in the wires, and/or feel what seems like the wires scraping and breaking inside the insulation then they are fried and will not be able to carry the full charge through the wires. Sometimes you may also notice the copper ends of the wires being brown instead of copper colored.
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Post by dickyh on Oct 7, 2015 7:47:09 GMT -5
The wires, have you checked the wires? I know from experience they can visually look good but on the inside of the insulation be all fried and beaten up. Find a nice quiet time of the day, or a quiet room, and try and move the wires around in your hands. If you hear crinkling sort of like a very small or tiny plastic bag contained in the wires, and/or feel what seems like the wires scraping and breaking inside the insulation then they are fried and will not be able to carry the full charge through the wires. Sometimes you may also notice the copper ends of the wires being brown instead of copper colored. I have checked and double checked every single wire...all seems to be fine. I have even gone to the extent of replacing the connectors. Still no Joy. |
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Post by lain on Oct 7, 2015 8:22:41 GMT -5
Then are you absolutely sure the battery is good? Charge the battery then put your meter on it and attempt to start your scooter. On a bad battery the voltage will drop a LOT, like more than half, while using the electric starter.
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Post by dickyh on Oct 7, 2015 9:52:42 GMT -5
Then are you absolutely sure the battery is good? Charge the battery then put your meter on it and attempt to start your scooter. On a bad battery the voltage will drop a LOT, like more than half, while using the electric starter. Thanks Will Try that tonight... |
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Post by tvnacman on Oct 8, 2015 1:56:42 GMT -5
I would suggest to get the stator and regulator wiring off the original harness. Take the battery out of the scooter disconnected. Then check the voltage if below 12.5vdc charge it. Check the voltage again after the charge is complete. Let it sit a few hours and check again. With a bad battery you will get low system voltage even if you have a solid charging system.
John
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Post by lain on Oct 8, 2015 10:16:36 GMT -5
Then are you absolutely sure the battery is good? Charge the battery then put your meter on it and attempt to start your scooter. On a bad battery the voltage will drop a LOT, like more than half, while using the electric starter. Thanks Will Try that tonight... So just to give you a little more details. A good battery will not drop below 9v. All my good batteries read between 12 and 13 volts without load and between 9 and 10 volts under the load of the starter motor. I have a bad battery that reads 11 without load and between 6 and 7 volts while under load and will not turn an engine over but will work for horn and lights and seems to be okay unless you use the starter. Pretty sure you need above 9v under load just like with a car for the starter motor and everything to work properly. |
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Post by dickyh on Oct 8, 2015 11:56:59 GMT -5
Thanks Will Try that tonight... So just to give you a little more details. A good battery will not drop below 9v. All my good batteries read between 12 and 13 volts without load and between 9 and 10 volts under the load of the starter motor. I have a bad battery that reads 11 without load and between 6 and 7 volts while under load and will not turn an engine over but will work for horn and lights and seems to be okay unless you use the starter. Pretty sure you need above 9v under load just like with a car for the starter motor and everything to work properly. so what should a fully charged battery read? I've read so many things. between 12.5 to 13.4 |
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Post by tvnacman on Oct 8, 2015 16:28:34 GMT -5
lets not look at what is said to be good. What do you have?
John
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Post by dickyh on Oct 8, 2015 17:26:05 GMT -5
so this morning I topped off the battery. It read 12.5V
Went to work and back 15 miles round trip, the battery read 11.97V when I got home
Hooked up the volt meter to start the scooter, voltage dropped to 10.16v when starting
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Post by tvnacman on Oct 9, 2015 6:40:28 GMT -5
so this morning I topped off the battery. It read 12.5V Went to work and back 15 miles round trip, the battery read 11.97V when I got home Hooked up the volt meter to start the scooter, voltage dropped to 10.16v when starting ok lets try this, take the battery out of the scooter ( keep it out of the scooter) give it a full slow charge. Then measure the voltage (do not put it back into the scooter) let it rest several hours (6-10). Then recheck the voltage and tell us what you have. John |
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Post by steve on Oct 10, 2015 9:16:44 GMT -5
There is an issue a lot of people face when changing to 11 pole stators:
The 11 pole stators have 3 power output wires that must go to the regulator: most have all three as yellow wires, some have yellow, pink, and white as the 3 output wires. They also have a green wire, which is ground, then the red and black wire that goes to the CDI, and the red and white wire from the pickup coil.
Here is the issue: most scoots only have TWO power wires in the harness that go to the regulator, and may or may not have a ground wire. The 6 wire regulator has 3 yellow wires coming out of it. You need to make sure that all 3 power wires from the stator are hooked up to the 3 yellow wires on the regulator. I cut the wire harnesses off of both the stator, and the regulator, and hooked everything up with bullet connectors. The green wire from the stator has to be hooked up to the green wire on the regulator. If you make sure everything is hooked up like that, then make sure the red wire from the regulator is going to the positive terminal on your battery, you will get at least 14v charging your battery. I recommend cutting off the wire harness, and running new wires, as I described.
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Post by tvnacman on Oct 10, 2015 9:33:11 GMT -5
There is an issue a lot of people face when changing to 11 pole stators: The 11 pole stators have 3 power output wires that must go to the regulator: most have all three as yellow wires, some have yellow, pink, and white as the 3 output wires. They also have a green wire, which is ground, then the red and black wire that goes to the CDI, and the red and white wire from the pickup coil. Here is the issue: most scoots only have TWO power wires in the harness that go to the regulator, and may or may not have a ground wire. The 6 wire regulator has 3 yellow wires coming out of it. You need to make sure that all 3 power wires from the stator are hooked up to the 3 yellow wires on the regulator. I cut the wire harnesses off of both the stator, and the regulator, and hooked everything up with bullet connectors. The green wire from the stator has to be hooked up to the green wire on the regulator. If you make sure everything is hooked up like that, then make sure the red wire from the regulator is going to the positive terminal on your battery, you will get at least 14v charging your battery. I recommend cutting off the wire harness, and running new wires, as I described. your a little premature here, a bad battery will cause the same symptom he is having. Encouraging someone with a charging problem to cut there harness is a pretty big step. John |
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Post by steve on Oct 10, 2015 11:29:51 GMT -5
True, John.
I was assuming he had gotten a new battery.
My apologies. You should definitely make sure the battery is not the issue. Try a battery you know is good, then check the wires.
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Post by dickyh on Oct 10, 2015 15:11:10 GMT -5
so this morning I topped off the battery. It read 12.5V Went to work and back 15 miles round trip, the battery read 11.97V when I got home Hooked up the volt meter to start the scooter, voltage dropped to 10.16v when starting ok lets try this, take the battery out of the scooter ( keep it out of the scooter) give it a full slow charge. Then measure the voltage (do not put it back into the scooter) let it rest several hours (6-10). Then recheck the voltage and tell us what you have. John so I got a new battery as it seems one of the cells were dying and charged the new battery and put it in. there was no significant increase in output. (about 12.4 at idle and 12.7 at 3000rpm) I've tried to learn how to diagnose the regulator and stator using a volt meter but it is all foreign to me... I checked the wires and connections on the regulator and the stator and all its fine. So I pulled the stator and looked to see if a wire was pinched or something and that's when I noticed that one of the coils had a broken winding- one of the copper wires was broken. this is a brand new stator and couldn't believe it when I saw it. I'm assuming this is what my problem is or is it? On another note... when I got a new regulator with the new stator it had 2 female plugs which my other had one male and one female, so I retrofitted the plug with the 3 yellow wires and had hooked it together. Now with all of this I am doubting myself if I have hooked those up right... is there a way to tell with a volt meter if in fact I have these hooked up correctly? the other plug has a green, red and red/black which matched up exactly so I know those are correct. And I also know that one of the yellow wires goes to the enricher (or so I've read) and I don't use that plug as I have fuel injection. My headlight works so I know at least one of the yellow wires are correct. Basic electrical I understand - positive to positive and and so forth but this thing has me baffled. |
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