Lights aren't working right: By richardthescooter3 (Read 2,451 times)

[cruiser]

If the wires are too hot, then something is pulling too much current. Your complaint is hot connectors which usually means too much resistance in the connector. The connectors may plug together tightly, but that doesn't mean you have a good electrical connection. The male and female metal pins inside the connectors have to fit tightly together. You may have to push the pins out of the connectors in order to tighten them with needle nose pliers.

Another common problem is the quality of the crimps on the metal connectors. Some people try soldering the connectors to improve the electrical connection.

[scooterdad154]

[replyingto=cruiser]cruiser[/replyingto]Yes, I failed to mention in last post but the R/R wires are hot as well.

[scooterdad154]

[replyingto=scooterdad154]scooterdad154[/replyingto]With the new R/R installed, I got a reading of 15.15v dc at the battery @2500 rpm, is that too high?

What should the regulator be limiting the voltage to?

[JR]

With a good hot battery 15.15 Vdc isn't too much. The linhai stator puts out very well and when the cooling fan comes on it'll drop to around 13.5 Vdc. I have a digital volt meter on mind and it goes as high as 16.0- V sometimes and I have all LED's in so the system doesn't demand as much voltage.

You asked about the black wire to the CDI? It actually is hot with the key on and since this is a DC powered CDI the CDI is fine simply because the scooter runs.

Now it's not unusual for a hot R/R this does two things rectifies the AC to a half wave DC output for charging the battery and running the lights and regulates the charge to the battery.

One of the first things that can make the R/R heat up excessively including the wires is poor grounding. The R/R must bolt up and ground properly, the black battery cable must hook up to the frame with no paint and ground properly......AND the engine itself MUST be grounded.

Another thing is the battery could have a weak cell and it's demanding a full charge.

You are correct in the black wire to the CDI reads voltage demand and tells the R/R when and how much to put out, any excessive not needed charging voltage is shunted to ground.

Also check the blocking diode for good connections. Lastly it has been known for one of the stator windings to get weak and shunt voltage to ground rare but it happens.

To test the stator simply unplug the R/R and check the yellow wires from one to another at idle.

Test like this:

Wire 1 to 2
Wire 1 to 3
Wire 2 to 3

Also test using the AC scale, you should test nearly or equally the same on each circuit, this is a 3-phase stator. Check at idle and at 5k rpm.

Should one leg be considerably different then it's time for a stator.


JR