I unfortunatly found this & understood "Exactly" what & how to test. I did follow the step by step diagnosis page repeatedly supplied here but I didn't think I was performing the tests right. How can I screw them up? It's easy! Any way here is what I found to help me. To bad the photo's where expired. But the write up works.
First off the Reg/Rect can when it goes bad Overcharge/Undercharge or not charge the Battery at all depending on what goes wrong with it
So to check the Stator is working ok..
Locate the 3 wires that come out of the Generator cover that are all the same color and follow them to the Plug, Disconnect at this plug because this is where you'll preform your testing...
Bike is a ZX6R J2 for Illustration only....And you can see the 3 Black wires centre of picture....Your looking for similar, I think the wires may be "YELLOW" on your Bike.
Here is the Plug disconnected and the end that is attached to the wires from the Stator is the one to test at.
Yours will probably look more like this white one from a ZX10R..With the 3 wires all inline, Same deal though
First test is to see if any of the 3 Phases have shorted to Ground.Ignition OFF.Connect Your Multi Meter as follows:-
Black Lead (Ground) to Battery Neg Post. See Picture..
Red Lead (Positive) to any ONE of the 3 Connections in the Plug..See Picture.
And you should get O Continuity showing on the meter or O.L as mine is showing set to the OHMS scale in the Picture below.
Repeat this on the remaining 2 connections and if your meter gives you a reading other than no continuity there's a problem right there because you have a Phase gone to ground....BAD
If they all check out ok then the next test is a Resistance check again on each Phase but this time with each other..
Leave your meter set to OHMS Scale.
To assist with the tests lets Number the 3 Connections 1,2 & 3it will make it easier to follow..
Ok connect the leads as follows i've done the first one in the Picture..
1~ RED LEAD
2~ BLACK LEAD
1~ RED LEAD
3~ BLACK LEAD
2~ RED LEAD
3~ BLACK LEAD
Take a reading for the 3 tests above and they should be between .3 and .6 OHMS for each of the 3 tests...Don't worry to much if there a touch under or over as i have only given an average as long as you get somewhere near there ok.
I have included a picture below of the reading i got when i measured the connections in the picture above..
Ok last test on the Stator is the same as the one you've just done but this time the Meter must be set to 100 VOLTS AC or more if your meter is incremented differently to mine, As long as it's around 100 your ok. .
On my meter in the Picture above i would have it set to A~ Because it is Auto Ranging it has no Values that i need to set it to, Yours may have A~ then probably 2 different AC Voltage ranges
At this point you need to be able to run your motor as this tests the output from the stator coil across the 3 Phases.Please make sure you can do this safely and still carry out your tests, Because there will be anywhere between 40 and 80 volts AC at that Plug your gonna be testing at so no PETROL slopping about whilst your touching the probes from the meter onto the connections as there can be small SPARKS when your making the connections.........
You set fire to your bike and i'm Gonna say i told you so....Please be carefull..
OK Fire Suit on ??? Lets play
1~ RED LEAD
2~ BLACK LEAD
1~ RED LEAD
3~ BLACK LEAD
2~ RED LEAD
3~ BLACK LEAD
Start the motor, Increase the revs to about 4k and take a reading for the 3 above....I find it easier to get an assistant to hold the revs and record the 3 sets of readings whilst i am making the connections.
Your looking for anywhere between 40 and 80 Volts AC the main thing is the 3 readings from the 3 Phases of the stator are all somewhere near the same as each other..
At this point if all the testing comes out GOOD i would suspect the REG/RECT has seen better days and replace it...
So with mine testing out at .8 ohms & 1 lead making about 5v opposed to the 40-80v suggested (per bike I suppose). The other 2 are making roughly 45v. So as best as I can tell I've got a dying not dead stator. Right!? Ah, what fun lies ahead.:rockon:
First off the Reg/Rect can when it goes bad Overcharge/Undercharge or not charge the Battery at all depending on what goes wrong with it
So to check the Stator is working ok..
Locate the 3 wires that come out of the Generator cover that are all the same color and follow them to the Plug, Disconnect at this plug because this is where you'll preform your testing...
Bike is a ZX6R J2 for Illustration only....And you can see the 3 Black wires centre of picture....Your looking for similar, I think the wires may be "YELLOW" on your Bike.
Here is the Plug disconnected and the end that is attached to the wires from the Stator is the one to test at.
Yours will probably look more like this white one from a ZX10R..With the 3 wires all inline, Same deal though
First test is to see if any of the 3 Phases have shorted to Ground.Ignition OFF.Connect Your Multi Meter as follows:-
Black Lead (Ground) to Battery Neg Post. See Picture..
Red Lead (Positive) to any ONE of the 3 Connections in the Plug..See Picture.
And you should get O Continuity showing on the meter or O.L as mine is showing set to the OHMS scale in the Picture below.
Repeat this on the remaining 2 connections and if your meter gives you a reading other than no continuity there's a problem right there because you have a Phase gone to ground....BAD
If they all check out ok then the next test is a Resistance check again on each Phase but this time with each other..
Leave your meter set to OHMS Scale.
To assist with the tests lets Number the 3 Connections 1,2 & 3it will make it easier to follow..
Ok connect the leads as follows i've done the first one in the Picture..
1~ RED LEAD
2~ BLACK LEAD
1~ RED LEAD
3~ BLACK LEAD
2~ RED LEAD
3~ BLACK LEAD
Take a reading for the 3 tests above and they should be between .3 and .6 OHMS for each of the 3 tests...Don't worry to much if there a touch under or over as i have only given an average as long as you get somewhere near there ok.
I have included a picture below of the reading i got when i measured the connections in the picture above..
Ok last test on the Stator is the same as the one you've just done but this time the Meter must be set to 100 VOLTS AC or more if your meter is incremented differently to mine, As long as it's around 100 your ok. .
On my meter in the Picture above i would have it set to A~ Because it is Auto Ranging it has no Values that i need to set it to, Yours may have A~ then probably 2 different AC Voltage ranges
At this point you need to be able to run your motor as this tests the output from the stator coil across the 3 Phases.Please make sure you can do this safely and still carry out your tests, Because there will be anywhere between 40 and 80 volts AC at that Plug your gonna be testing at so no PETROL slopping about whilst your touching the probes from the meter onto the connections as there can be small SPARKS when your making the connections.........
You set fire to your bike and i'm Gonna say i told you so....Please be carefull..
OK Fire Suit on ??? Lets play
1~ RED LEAD
2~ BLACK LEAD
1~ RED LEAD
3~ BLACK LEAD
2~ RED LEAD
3~ BLACK LEAD
Start the motor, Increase the revs to about 4k and take a reading for the 3 above....I find it easier to get an assistant to hold the revs and record the 3 sets of readings whilst i am making the connections.
Your looking for anywhere between 40 and 80 Volts AC the main thing is the 3 readings from the 3 Phases of the stator are all somewhere near the same as each other..
At this point if all the testing comes out GOOD i would suspect the REG/RECT has seen better days and replace it...
So with mine testing out at .8 ohms & 1 lead making about 5v opposed to the 40-80v suggested (per bike I suppose). The other 2 are making roughly 45v. So as best as I can tell I've got a dying not dead stator. Right!? Ah, what fun lies ahead.:rockon: