Bad stator or R/R ? By daven68 (Read 7,035 times)

[daven68]

Hi again guys, think I have the over heating issue solved( thanks for all the help), but now realized a new problem (does this ever end?).
Scooter is again a Jonway yy250t-2 and it is apparently not charging. Ruled out the battery being bad and from research it seems to be down to the stator and/or the regulator rectifier. Battery shows about 12.4 volts with no lights or fans on . when the cooling fan comes on it drops to about 11.6 , lights drop it even more. Looks like I have been riding around on pure batt power for a little while now. Also while the engine is running if I disconnect the battery it immediately kills the engine. Any thoughts on how to test which one of these parts has gone belly up?
Thanks again.

[tvnacman]

the harnes from the engine to the regulator , on the stator side how many wires are there and what color are they ? If i'am looking at the correct diagram it looks like a dc cdi , with your charging out that is why it stalls out .

charge your battery Your going to have to keep it running for some trouble shooting . There is going to be a plug between the stator and regulator on the stator side it will have 3 yellow and a green , you need to find that plug . then come back and let ue know . have your meter ready to go as well .

Loacte your starter solinoid and check the 20A fuse . Look under your seat and check the fuses in the fuse box .

John

[alleyoop]

Have to find it but I believe we have how to test which one is the CULPRIT the Stator or the R/R.

You can find out if it is chargeing or not , start it up and rev it up a little and see what the battery reads it should show the voltage going up over 13+ as you rev it up.
And yes yours appears to be a DC CDI if you disconnect the battery and it dies.

If not JR knows how to test to find out which one is the CULPRIT the R/R or the stator.
Alleyoop

Found it:
thescooterprofessor.proboards.com/index.cgi?board=elec&action=display&thread=87

[tvnacman]

unplug the stator and acv readings yellow to yellow 40 - 60 vac if not stator is bad .

John

[JR]

Total DC system, unhook the battery or dead battery = no run.

Stator test:

thescooterprofessor.proboards.com/index.cgi?board=gele&action=display&thread=1140

Also one thing all are forgetting, this scooter has the blocking diode, if it is bad (open) then no charge to the battery.

It's the little small aluminum box right by the R/R and has two wires.

Simple test of it, just unplug it and jump the two wires together that plugged into it. Don't pannick the headlights will immediately come on.

Start the scooter and test the voltage output on the battery again at idle and revved up. If it's 13.5 Vdc or above you've found the problem. If not then test the stator and go from there.

JR

[daven68]

Thanks for all the suggestions guys, I`ll try them and let you know how it turns out. Hope it`s the RR thats a quick , easy fix on this bike. I don`t have a clue on how to change out the stator.

[scootforfun]

wow, talk about total luck out...We discovered the R/R was disconnected.

Problem solved. Tested at 13.89. Not sure if we did it, or the shop he had it in recently forgot to connect it back. But who cares, we're back on the road, and going now to put his bike under a more stressful test for the overheating, which we believe is also fixed. We'll know more in about a couple hours.

And JR, his bike does indeed run with the battery disconnected. We tested that too, once the R/R was plugged back up and started the engine. Now a bizzare problem: he shut the key off, and the engine kept running till he hit the kill switch.

[daven68]

Hey guys, thanks for all the great info. Thankfully , as scootforfun stated we got the problem solved. As we disassembled the side panels again to start on the tests we noticed a disconnected plug a few inches away from the RR,which we originally thought was an accessory plug (there seems to be a few of them hanging around) plugged it back together and bingo! She`s charging like a champ. ;DNeither of us remember touching it but it`s possible we did or it happened the last time in the shop. Strange thing now is the engine not cutting off when the key is removed Lights and fan cut off but not the engine. Oh well I guess it`s not a huge deal since it cuts off by the kill switch and will not start again untill the key is back in the ignition position so at least that way it cant be driven away without the key. now back to the overheating problem.

[JR]

Point blank you've got the remote on and that's the reason it will not shut off with the key AND the reason it will run with the battery disconnected.

What happens when the remote is on voltage is supplied to the CDI via the black wire from the ignition which gets 12 volts from the red wire that comes off of the R/R. The remote actually bypasses the key switch and can be on and take away your key function.

You have got to reset your remote or unhook it and in this mode the scooter can be dangerous because it has been known to reset itself running down the road and instantly kill the engine. Not fun if your'e going 60 MPH.

This is a DC powered CDI unless someone jury rigged a AC one in and I doubt this.

Wire colors to the CDI are

gray/white = kill wire
green = ground
red/white = pulse wire from stator to CDI
yellow/black = coil feed wire
Black = 12Vdc from ignition = CDI hot wire.

Unplug the black wire test it for 12 volts and watch the scooter NOT run or even start.

If the remote is not the problem then the black wire is crossed with the red wire and getting voltage all the time.

JR

[daven68]

Ratts... why cant anything be easy? This is all way beyond my level of expertise.
I don`t have a remote. I`m going from memory here so I may be off but the plug we hooked up was a 3 prong 3 wire , 2 greens and a white or yellow I believe ,I could be wrong. but it fit perfectly and seemed to be dangling near each other.one of them coming directly off the RR. What I don`t understand is why the batt now shows the proper charging on the volt meter? We did see the blocking diode you spoke of but did not get that far since we connected the plug first. I don`t want to do anything dangerous or damage the bike so does that mean i`m back to a bad RR, stator or blocking diode again? It may be a few days before I have the chance to work on this again. Also forgive my ignorance but just what is the CDI and where is it located? Thanks again.

[JR]

Here is something that might help a lot and it's the wiring diagram:

thescooterprofessor.proboards.com/index.cgi?board=250g&action=display&thread=430

Your scooter is the first one listed the yy250t scooter. Cruiser and I made this diagram and went by his scooter a exact copy of yours. The CDI module send power to your coil so the spark plug will fire. It is generally located under the seat (is on my scooter) or by the coil and R/R area.

Here is a picture of it;



When scootforrun said the scooter would run with the battery unhooked it tells me you've got something wrong. Now most of these come with a remote and most people just unhook them. The remote module is generally located behind the headlights.

On the CDI the black wire is the power wire to it and again supplies 12 volts to the unit. It is DC and does not get it's power from the stator like a AC powered unit does.

So if your scooter will run with the battery disconnected then you've got a issue.

JR

[alleyoop]

[daven68]

Thanks JR, we will look into this further. Question, does it matter that my scooter is a yy250t-2 not just a yy250t and what is the difference?

[daven68]

Thanks alleyoop , I think i saw that hanging behind the RR.

[JR]

May 6, 2012 21:02:32 GMT -6 daven68 said:

Thanks JR, we will look into this further. Question, does it matter that my scooter is a yy250t-2 not just a yy250t and what is the difference?

Is this your scooter?

.shenkemotor.com/YY250T-2(Navigator-250).html" rel="nofollow" target="_blank">.shenkemotor.com/YY250T-2(Navigator-250).html

If it is and it has the vertical 244cc engine then the burping and such is the same as the others and it needs the thermostat.

This scooter is called by many names like a lot of scooters are in fact this is the Bali 250 style also.

It shows no alarm. Did you get this scooter used? You said you're already found the diode and to my knowledge the wiring is the same as the YY250T.

Find the CDI and that will tell us a lot and verify the R/R colors for me. Also does this scooter have a on/off headlight switch or does the lights come on automatically when started?

JR