Still not Charging back to round1 By damin69 (Read 13,300 times)

[damin69]

I just do not under stand this.

Ok full charge battery. shows voltage 12.82

Start scooter drops comes back up to 12.58 stays there while ideling at 5000 rpm voltage drops to between 12.49 and 12.52

Have replaced regulator and Diode NOW and still does the same thing. I thought I had it last week had it stripped down and checked all connections again. Then did the diode check and the voltage came up. Now I get the new diode install and now voltage just stays flat. I tried jumping where the diode is again but this time the voltage just stayed the same. This sucks.

[damin69]

Ok according to the RR/Stator trouble shooting the problem is in this line I have drawn over in Red. I have a stinking suspicion it is in the dang wire that goes to that stupid clock. That thing goes haywire all the dang time and does not keep time. Where I'm confused is I don't see the Fuse for the wire that connects from the battery to the starter relay.

[Smorkle]

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.

[damin69]

Ok It blew the fuse that goes to the solenoid once. Could be be that junky fuse holder giving me the charging problem?

[Cruiser]

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

[damin69]

Ok will try again. Replaced the barrel fuse with a good spade fuse. Then was showing signs of not getting a decent ground back to the RR so ran a ground wire up to battery Now I am finally getting voltage that comes up when the rpms come up instead of going down. And the voltage is above the battery voltage when I start so I am hopeing that means it is going to charge now.

[damin69]

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. :-(

[yoster]

Damin, your scooter must be an exact clone of mine. I've experienced every single thing you have, including the mysterious "touch random wires and it dies!!" The good news is I did finally solve the latter problem. It was the two wires coming off the stator going to the CDI; the connector itself. You would barely graze them and it would kill the scooter, but it NEVER happened when I was ever riding! I cut the stock connector off and made a quick-connect crimp thing.

As far as your charging problem, like I said, I replaced the diode with a relay and that helped.

At least they call them a relay on some sites, it's still a diode:

www.scooterparts4less.com/Moped_Web/GY6_Relay.htm

From that point, it was try about 6 different regulators until I found one that worked well. Some would charge at 17v and overheat, then stop charging altogether, others wouldn't charge at all, others would charge PERFECTLY at 14.5v then DIE after a week. I FINALLY have one that works well, but, I'm too lazy to put it on because the one I currently have (the original stock one) is doing well enough where it juuuuust barely keeps the batter maintained. For some reason if I put the diode back, it ruins everything again.

Hope you find some special thing that fixes it once and for all... i'd be interested!

[damin69]

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.

[damin69]

Ok I did a little check coming directly out of the regulator I am getting 13.5 - 14 volts. Could I not run a positive lead with a fuse in it from there to my Battery to get my battery to charge?
I am talking about running a wire from this brown lead pictured directly to the positive on the battery with a fuse in the line.

[Smorkle]

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. ÷)

[Smorkle]

This is what I found when I was looking at my stator wires last year when I did my engine rebuild:





I fixed them with some new crimp on lugs:

[damin69]

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.

[damin69]

I did a bit more testing before I finished what I was thinking of doing. I had the wire soldered in place and fuse holder in. Before I put the fuse In I decided to check the voltages again. That is where everything went to crap again. OK so now I find that at the Positive out of the RR while at Idol I get 13.5+ volts as soon as I bring the RPMs up the voltage drops to 9volts then comes up while at 5000 rpm steady it is holding about 12.4 volts. I tried all 3 regulators I have does the same thing.

I got the direct plug in Diode/relay.

[damin69]

Jun 19, 2010 17:18:00 GMT -6 yoster said:

Damin, your scooter must be an exact clone of mine. I've experienced every single thing you have, including the mysterious "touch random wires and it dies!!" The good news is I did finally solve the latter problem. It was the two wires coming off the stator going to the CDI; the connector itself. You would barely graze them and it would kill the scooter, but it NEVER happened when I was ever riding! I cut the stock connector off and made a quick-connect crimp thing.

As far as your charging problem, like I said, I replaced the diode with a relay and that helped. From that point, it was try about 6 different regulators until I found one that worked well. Some would charge at 17v and overheat, then stop charging altogether, others wouldn't charge at all, others would charge PERFECTLY at 14.5v then DIE after a week. I FINALLY have one that works well, but, I'm too lazy to put it on because the one I currently have (the original stock one) is doing well enough where it juuuuust barely keeps the batter maintained. For some reason if I put the diode back, it ruins everything again.

Hope you find some special thing that fixes it once and for all... i'd be interested!

How exactly did you replace with a relay. Can you give me a link to the relay you are using. I am not ruling out another bad diode. I just went back out and did the diode test again. I pulled the diode started it up and checked voltage at the Positive out put it was 13.8 at idel and 14.1 at 5000 rpm. But still am not getting the voltage like that at the Battery which has me puzzled. I will get that sorted as soon as I get the voltage constant at the postive on the RR.