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Author Topic: charging system problems!  (Read 515 times)

Offline Bajafanboy

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charging system problems!
« on: June 21, 2017, 03:14:40 PM »
hi, I'm new to the forum so hello everyone!
I have a 01 ds650 that I got about 8 months ago, I love the thing and from the engine back it's in pretty good shape, the front end is a little banged up but that's a story for another day.
anyway, on to the subject at hand, I've been having problems with the charging system, I've cooked 4 batteries in the last 6 months.
so all signs pointed to the regulator rectifier, I got a new battery and an AFTERMARKET regulator rectifier, in other words, cheap,
I put on the battery and the regulator then started the bomber and got out the multimeter.
voltage was around 14.5v at idle 16-17v at 3500rpm+, wich is way too high, the service manual says 15v max, I did the same test with the old regulator and the result was about the same but hears where things get weird, I decided to ride up the road so I wouldn't be bothering anyone with the noise, I started testing the voltage again and like magic the new regulator was working perfectly, 14.5v even at max rpm, and before you ask no the multimeter was not on hold haha.
so everything seemed to be fine for about a week but then I was riding  and the battery went dead at firs I thought the regulator was broken but it was just the connector that was broken, so I limped it home and upon further inspection,  I noticed that aside from the negative pin being broken in half the end of the pin was also slightly melted. bad connection? maybe, so I decided to do some experimenting. I did a direct solder on the negative side and started testing the voltage again, now it was charging but the voltage was too high like before, I think I saw 18v at one point,
after  that, I put the old regulator on and tested it just to see and like magic now the old one works around 13.5v at idle and 14.5v max.
at this point, I feel like my ds just hates me haha.
So, any ideas, I was thinking of just putting a secondary regulator on it as that would be the cheapest option, was also going to see about using a Mosfet regulator rectifier instead of the stock shunt type regulator rectifier
« Last Edit: June 21, 2017, 05:16:32 PM by Bajafanboy »

Offline ACEISBACK

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Re: charging system problems!
« Reply #1 on: June 21, 2017, 07:35:52 PM »
Welcome aboard.
Have you checked your ground points? They coated these frames pretty heavily so it helps to do a little bit of grinding in order to get a better contact.
Your problem is before the CDI so somewhere from the stator back to the battery is where you have to decipher. BigRay will chime in when he sees this post, he'll have a better answer than I.
If you can read this, thank a Teacher. If you can read this in English, thank a Marine.

Offline Bajafanboy

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Re: charging system problems!
« Reply #2 on: June 21, 2017, 08:44:30 PM »
I've actually already cleaned all the connections going from the regulator rectifier and to the frame and battery.
also checked grounding with a multimeter, checked from battery to frame and from battery to the engine, I believe both had 0 resistance but I'll have to check again.



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Offline persom55

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Re: charging system problems!
« Reply #3 on: June 22, 2017, 02:53:44 PM »
Welcome aboard

The way I'm thinking of this, a red flag went off when I read "cheap" rectifier haha
It may be that the original rec. has failing solder connections in it. So it would work sometimes and other times not

The cheap one you bought may have been made so poorly that it too is suffering from failing connections inside it

Perhaps you might just have to buy a quality one.
Or, You could technically wire up an reg/rec from any other machine with 3 wires from the stator and 2 wires to the battery
Some members on here have hard wires regs from can am watercraft.
I thinke either bigray or aceisback had mentioned that before

Offline Bajafanboy

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Re: charging system problems!
« Reply #4 on: June 22, 2017, 03:13:21 PM »
One thing I've noticed when looking for a reg/rec, almost none of them have reviews, and the ones that do, people seem to have the same problem as me.



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Offline persom55

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Re: charging system problems!
« Reply #5 on: June 22, 2017, 03:35:06 PM »
Bingo

I've had good luck buying used Oem tested working ones from eBay

Offline Bajafanboy

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Re: charging system problems!
« Reply #6 on: June 22, 2017, 03:36:58 PM »
I think you're right a bad solder joint is more than likely the culprit.
The cheap reg/rec I bought was from China haha.
I tried to find one that said it was from Taiwan or Japan but unfortunately I couldn't so oem or used is most likely my only option,


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Offline Bajafanboy

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Re: charging system problems!
« Reply #7 on: June 22, 2017, 03:47:07 PM »
One thing I'm going to try just for fun, is to remove the epoxy by boiling the original reg/rec in water and see if it can be repaired.
Thanks for the input so far


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Offline persom55

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Re: charging system problems!
« Reply #8 on: June 22, 2017, 05:13:49 PM »
Be careful boiling it, I'm not exactly sure what kind of components are in there. If there's any capacitors in these they could potentially explode if their of a certain type. Again not sure there are capacitors in there but just be careful.
Could try brake cleaner or acetone
Maybe even methyl ethyl ketone

Offline Bajafanboy

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charging system problems!
« Reply #9 on: June 22, 2017, 05:23:38 PM »
I believe it's just diodes BJTs and maybe resistors,
That's what's in linear regulators at least, switching regulators on the other hand do have some more electronics including capacitors.
I'll be sure to do some more research before attempting that just to be on the safe side

Offline bob

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Re: charging system problems!
« Reply #10 on: July 14, 2017, 05:56:28 PM »
mother of god, this is the worst dry spell ever. someone needs to tell some lies or something. its almost time for dunefest at winchester bay.

 

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