Board logo

Hayabusa charging problems
dave_424 - 14/8/15 at 12:04 PM

Hi guys, I've got a hayabusa enigne all wired up. Starts and runs fine but it isn't charging.

If I disconnect the wires from the stator and test between any of the three yellow wires, I get approx 20v at idle and 60-80v at higher revs. But as soon as I connect it back into the loom and do the test again, they drop to 11v at idle with not much rise.

I changed the voltage regulator and still the same problem. Doing a diode test on both regulators, old and new, they all test good with pretty consistent readings.

None of the yellow stator wires short to ground. The red wire at the regulator plug has continuity to the battery positive post and the black/white has continuity to negative terminal/chassis/engine block

Also one other problem that probably isn't related, is that I believe my loom has a connector for an oxygen sensor but that isn't wired in yet. I see a lot of places offer an o2 eliminator plug so is it really needed?

Any info would be much appreciated

Dave

MikeRJ - 14/8/15 at 05:40 PM

The regulator on a bike works by shorting the stator outputs together as soon as the battery voltage rises above a certain threshold. Unless you have a true RMS reading meter, you won't be seeing the true voltage on the stator side since the waveform won't be sinusoidal, and the loaded stator voltage is a fairly pointless thing to measure anyway.

What is the actual problem you are having, is the battery not charging ? What is the battery voltage at idle and at higher RPM?

[Edited on 14/8/15 by MikeRJ]

dave_424 - 14/8/15 at 05:47 PM

Following some of the stator tests in the service manual, Fluke multimeter set to AC volts I'm getting the correct voltage that the manual states between any of the yellow wires with the regulator disconnected.

Actual problem is that the battery doesn't charge. At idle I see approx 11.8V and at around 5k it might rise to 12v

MikeRJ - 14/8/15 at 06:42 PM

quote:
Originally posted by dave_424
Following some of the stator tests in the service manual, Fluke multimeter set to AC volts I'm getting the correct voltage that the manual states between any of the yellow wires with the regulator disconnected.

Actual problem is that the battery doesn't charge. At idle I see approx 11.8V and at around 5k it might rise to 12v


The open (i.e. unloaded) circuit stator test sounds fine, about 80v is exactly what I would expect at high RPM and you get a sinusoidal waveform so any meter should give reasonably accurate results. It's the loaded stator voltage that won't mean much with a basic multimeter.

Is this a simple 5 wire regulator (three stator wires for in put and two DC wires for output)? Some regulators have extra wires for sense connections, and they won't work properly if not connected.

Are they both genuine Suzuki regulators? You'd hardly believe it, but there are counterfeit Chinese regulators around that have almost nothing inside them apart from sand to make them heavy.

dave_424 - 14/8/15 at 06:49 PM

Only 5 wires, 3 yellow from the stator, one red that is power out and black/white which is ground.

I believe the original one is genuine but I think the one I brought isn't.

Both regulators when tested using the diode setting on the multimeter give the same kind of readings, the original seems slightly more consistent but they are both within 10 of a 550 figure that I believe is ohms.

I've read somewhere that somebody had an inline fuse that was blown, and also another person said that the fuse in the starter relay was blown, but on my ZX9 engine a fuse blown there doesn't give any power to whole loom. I think I'm going to strip the loom in that area and make sure everything is okay.