Lights drain battery

[theoneandonlymin]

Any clues where to look on an XT600E 3tb that is draining / killing the battery when the lights are on ? Getting nearly 14 V until the lights are on and then the reading starts sliding downwards.
The AA recovery man described it as the alternator breaking down under load ???

Cheers
Min

[Walkabout]

" The AA recovery man described it as the alternator breaking down under load "

He might be right; there again, he might be wrong - most of these folks out on the road nowadays with the AA/RAC are quick to get you off the highway and less inclined to fix modern, complex vehicles on the side of the road.
Generally, they are even less keen when called out to a bike, even one with old school technology!

Anyway, for your current issue, you should explain if the engine is running when you check the symptoms; basically, provide as much relevant information as possible.

The state of charge/discharge of the battery depends on such factors.

[Jens Eskildsen]

Its probably the regtifier going bad....

[dan66]

Originally Posted by Jens Eskildsen

Its probably the regtifier going bad....

I agree with Jens - possibly the Rectifier/Regulator. I had the same problem on my 4pt. I put a new Rectifier on and now its fine, worth trying first as its a cheap and easy fix costing from about £15.

Dan

[theoneandonlymin]

Tested the new stator and compared it to the one still in the bike . It is the stator going by the multimeter.

Thanks for all your replies,
Min

[bacardi23]

theoneandonlymin don't forget to follow the steps I mentioned in order to replace the stator and get it right at the first try

[Walkabout]

Originally Posted by theoneandonlymin

It is the stator going by the multimeter.

When used correctly multimeters tell the truth that is invisible to the naked eye.
The logic/flow diagram for fault finding assists of course.

Just poking about in the internet, I came upon this, which collaborates your flow chart:-
Must-do Tips BEFORE installing a Rectifier/Regulator
Check the AC output of the stator
Check that the stator is not grounded.
Replace any burned or corroded connectors on stator & rec/reg
Check & repair any melted wiring
Use hi-Temp Dielectric grease on all connectors

found here:-
http://ricksmotorsportelectrics.com/...ier-regulators

[theoneandonlymin]

Battery fully charged on trickle/load charger this morning. Didn't take voltage but it should have been 13.8v or higher.
24 miles later, no headlights being used 13.2 V

Tickover no lights :14.15 V
Headlight on : 13.2V which after a few minutes is down to 12.7V

Then I took it out twice , 2 miles commuting run 30mph 3rd gear to keep the revs up a bit;

No Lights : Start 13.42 V returned with 13.85 V

Lights : Start 13.85 V returned with 12.60 V

Same route same traffic same ....


Thanks
Min

[Walkabout]

So,
Your tests indicate that the bike is charging when the lights are off but it is not charging when the electrical load is higher, with the headlight on.

As Jens says, maybe the RR is failing.

Answers nearly always generate more questions!

Do you have a wiring diagram for this bike?
How is the condition of the wiring loom?
Are all the earth/ground connections good?
Is the battery a known quantity - a good 'un?
Have you changed anything recently?
(An electrical fault might be the result of a particular single event or a gradual deterioration in the loom or a component).

Have a read through this thread for some ideas about fault finding:-
http://www.horizonsunlimited.com/hub...charging-67094
The beginning and the end are most relevant, unless your loom is as bad as the one discussed in that thread.

You need to be logical with mechanical problems and even more logical in faults of electrical circuits.

[Warin]

It is relatively simple to do some resistance readings on the stator to check that it is ok. After that suspect rectifier/regulator. Use your manual to find the readings you should get.

You don't have supper bright headlight globes do you? Nor driving lights?

[steveloomis]

Sounds like the regulator/rectifier is dying and cannot keep up with the load if the lights are on.

What is the charging voltage both with light off and light on, idle and higher speed. It should keep the voltage above 13.5 under load if working correctly and perhaps more.

[Walkabout]

Originally Posted by Walkabout

S
Do you have a wiring diagram for this bike?

I guess I should have asked, also, do you have a workshop manual?

I've had the side cover off the generator of a TTR600 (it has the same engine, more or less) but I didn't change the stator.
What I do remember is:-
1. There is oil in there - I think I tipped the bike over on its' side to stop it running out, but I may have drained it (someone else can add to this point).
2. I definitely got a new paper gasket for that cover on the basis that they are one-use only and it is a PITA to put it all back together to then find that there is oil leaking/weeping.

[kentfallen]

Don't forget it MAY be a simple knackered battery!

I had exactly the same problem with one of mine - went through the obvious (alternator, coil, reg, etc) above and problem still present.

The nearly new battery was fading under load.

Replaced it with a better German battery and problem sorted.

[bacardi23]

yes, it's the stator..

1-Put the bike on it's side remove the small e-start motor cover as there is ONE bolt in there that you need to take out and can only access from there!

2-Remove the stator coveruse a screwdriver that fits perfectly on the bolts or you will strip them!

3-If the gasket is damaged, replace it with a new one! I also used a very thin layer of liquidgasket on both engine part and stator cover!
If you put some on the engine part, it will hold the new gasket perfectly in place when you put the stator cover back on!

4- When you're putting the stator cover back on, be careful not to crush the neutral cable between the engine part and the stator cover!

Keep in mind that the regulator/rectifier might also be faulty, so check it out!
And the battery is probably wasted aswell.... get an AGM battery or one of those Li-on/Lipo whatever batteries: Lithium Ionen Batterie Yamaha XT 600 E '90 '03 HJTX9 FP | eBay

Vando

[theoneandonlymin]

A few days later than anticipated but wish that I had a chance last week.
Drain oil , cover off , remove stator, clipped the wires to aid removal . The screw holding the wire shield was that tight the head sheared off ! Never mind.
Put the old rotor beside the new. Wrong size !!!!
New stator : 115mmx54mm
Old stator : 103mm x 42mm
Of course Electrex is shut for the weekend.
This one is the same size ;
Electrex World - Motorcycle electrical parts for Japanese, European & British bikes | Electrex World Ltd G73
Is this correct or do I wait for them to tell me on Monday???
I was sent a G45 .
At least I have a few spare days to sort it.

Secondly when I took the cover off there was an O ring loose inside the flywheel. Not mashed up. There was one on the cover as well where it should be. Where did it come from ?

Min