Still not Charging back to round1  By  damin69 (Read 13,276 times)

I'm very interested in your solution cause I may be having the exact same problem.

I installed a volt meter on mine and I have noticed that it seems to get full charge of about 14-15volts intermitantly. Sometimes it gets a good charge and then sometimes it doesn't.

Keep me posted.

This could certainly be a problem area. I would change the glass type fuse to this style which makes a positive connection unaffected by vibration:

www.radioshack.com/product/index.jsp?productId=2103778

I am at my whits end now. Man every time I take one step forward 2 steps back. Still NOT charging properly. I will ride for an hour and it will kill the battery enough that it will not start the scooter if I shut it off. Then the next time I can ride stop shut off and it starts right back up. Well today it was both. go figure. Had a full day of scooting planned while caching. Drove up to first cache about 40 min away. shut off scooter it would not start back up with out jumping it. I carry a battery with me just for this reason.

SO I was so ticked off I cut the day short told my dad sorry I have to get this dang thing chargeing. Came home put up on the lift and stripped to Frame again. took all the loom off the wires. All the connections that are wired hooked together and crimped I soldered. Still can not get the damn thing to put out over 12.83 volts at 5000 RPMs. I checked all the grounds loosened them up and re-tightened them down. I pulled the fuse panel out to the side of the scooter with the wires took it all apart. I replaced ALL of the fuses. Still nothing. Took all the wires apart put them back together same results.

Now comes something that is weird and I have a feeling is what is causing the problem but I can not find what is doing it. Ok through out this whole thing the scooter has ALWAYS ran great never given me any problems running. Well with the scooter running all the wires spread out and I move them something Kills the scooter it just quits. I just can NOT find the wire that is doing it. The wires I move are right in front of the regulator. I thought it was one of the ground wires but I started it back up and kept messing with it and would not do it again .

I would just love a stick of Dynamite right now. :-(

Ok well I found the culprit to the cutting out issue but that did noting for the charging. Both plug to CDI were firm. I found the 2 wires coming from Stator the plug was very loose. I pulled the connectors out and tightened them up No more cutting out when moving wires around. But that did not change the charging issue.

I found a better wiring diagram that I referred to than yours.

It looks as though the regulator goes to the main fuse then off straight to the battery. I'll bet your fuse block has loose connectors. I would check continuity from the brown wire you show in the picture to the main fuse, then from the main fuse to the battery. I'll just bet since you seem to have good voltage at the regulator that there is some sort of a connector problem (or loose crimp, bad wire, etc.) between the regulator and battery.

Make sure that the rectifier/regulator is grounded properly and that the battery is grounded properly. Sometimes you need to scrape some paint or rust off under the grounding connector to make sure it's getting good contact.




I hope this is of any assistance to you. ÷)

Glad my wiring does not look like that. I pulled the fuse box all the way out to the side to check all the wiring and connections. I replaced ALL of the fuses. And soldered all of the crimp connections all the way to the fuse box. That is what does not make any sense to have a voltage drop that much from the Regulator back to the Battery. I have taken off all the grounds and reconnected. Made sure there was no rust under any of them.