Heres a close look at the r/r with relay removed:
and of the other side of the relay where the conections are:
and of the other side of the relay where the conections are:
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I really only saw 2 wires coming from the stator. one was orange and the other black, the papers said there were 3.
also the r/r only has one wire coming from it too..
can anyone maybe clear up whats going on here? i have better/closer pics of that relay ready to go, just didnt want to clutter up the thread with a bunch of consecutive posts.Comment
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Yes, you have a rats nest of wires going to a aftermarket (non o.e.m.) relay. god knows what it's for.
didn't see any battery cables going and coming from it, but it looks like a starter relay.
the sheath covering the wires from the stator should have three wires inside it. (yellow-white/red-white/green)
the aluminum finned piece LOOKS to be the R/R. how many wires are coming out of it?, it should have minimum of four wires.
let me see if I can find a wiring diagram.Last edited by rustybronco; 11-13-2008, 03:54 PM.Comment
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well i can tell you that the bike has a new ignition button on it, so that could very well be what the crazy relay is for. (meaning- the stock swtich built into the grip is disconnected and a new one is bolted on next to it. ) i think there is a battery cable going to it (red cable out the bottom), im back at work to ill check when i get home and let you know all the connections. didnt know it was aftermarket or i would have gotten more info for you guys.
the aluminim thing, suspect r/r has only one wire- that purple one , which connects to the blue/white wire you can see in the relay.
from the stator, there appears to be 2 wires one black (bottom wire), and one orange with a yellow connector (top).
Last edited by Guest; 11-13-2008, 04:12 PM.Comment
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there are three wires from the alternator (stator) white/blue, white/green, yellow...
R/R has four wires + the case ground.Comment
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I found the connection where the stator meets regulator, it was at the top of the bike, the regulator wires were ruining behind another compontent. 3stator wires, 5 r/r including the ground.
In the process of checking the wires and connectors and then get to testing...Comment
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On my 250, I found a short in the wiring harness under the seat. The ground wire inside the wrapped harness had been pressed against a 12V source, and the insulation had failed. This had zapped both the R/R and the stator.
If/when you find the R/R and stator are toast, don't forget to look for the original cause. Because of the PO's mods, you'll have more to do, of course.
Do you have a wiring diagram? Actually the 250's wiring is quite similar to the larger bikes - close enough to find your way about.Comment
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i do have wiring diagrams in my manual.
i checked the wires and connections last night- they all seem to be ok. didnt get to test the components yet, letting the battery charge up and ill check the stator and r/r tonight or saturday.
i talked to another member last night, and he suggested , while im at it, to upgrade some of the connectors (just get new spade connectors)... any thoughts on that from anyone else?
didnt find anything faulty, BUT the r/r was grounded to the frame and not to the (-) battery terminal - thats something i want to reroute correct?
by grounding to the - terminal, it creates less resistance, according to the stator papers....Last edited by Guest; 11-14-2008, 11:40 AM.Comment
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I grabbed a Battery Tender, fully recharged the battery and started my tests.
Fortunately- very early on I found a poorly connected ground wire, I was able to re-do that properly and checked the circuits. Everything turned out ok, and the bike started on one push.
I took it out 3 different times today, for about 5 miles each ride, and it ran great. For now, no major component faults.Comment
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Now for the question that begs to be answered.
What is the charging system voltage, measured at the battery @? rpm's...Comment
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Cooking with electrons
Hi Mr. ChicagS25o,
Here are some PDF files (with pictures) I put together when I was working on the charging system of my bike. Maybe they'll help you. I've collected a lot of wisdom from the gurus here and saved it at my little BikeCliff website.
Stator TestComment
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well its been a while, i was able to squeeze out a couple extra weeks of riding by just charging the battery every so often.
now that there's snow and salt out, i ran the diagnostic tests, where i stand right now, my stator is bad.
At 2500 rpm the voltage was 12.29. I went thru the other initial tests according to the stator papers, and then began section B (the actual stator tests). During all of this i replaced a few connectors.
The resistance between all of the stator legs was 0.2. This points to bad stator.
There was infinite resistance when i tested the continuity to the ground.
The last was for the AC voltage output....not all the outputs were equal to each other (one pair was lower than the other 2 pair), and was below 60v volts.
So where i stand based on the stator papers/bass cliffs pictorial is that i need to replace the stator.
Unless anyone has any opposing advice, i will be ordering one.Comment
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