Finally had a failure on my TE511

[Motosportz]

Was just bragging the other day how stone reliable this bike has been. Fired right up and ran great but noticed the volt gauge on my trailtech read low. Got lower and lower. Not charging. Think it is the regulator but I suck at electrical. Got a call into Bills for one. Sucks as the bike runs great and the Zipty suspension was feeling hero. Crap. Oh well.

Anyone got a line on where to get a rec/reg for these? Any crossover? trailtech has a universal one but they are not sure it will work and I would have to splice it in. That does not sound good.

Help?

Thanks
Kelly

 

[Micfasto]

Test with a meter to see what it is first. Battery first. test it to get voltage while off. Them start the bike and the reading should be higher while running. If it is higher while running then your charging system is good and you may have a battery that is going bad. (that is an easy fix, a new battery)



If it is not higher it could be several things.

Start with the easiest all the connections. start at the battery and work you way back to the regulator/rectifier some times the pins in the connectors can work they way out. The plastic plug is locked but the pin worked its way loose.

Then check the regulator/rectifier

start watching at 10:20 yours will be different with wires and plugs but the concept is the same.

If the regulator/rectifier is good then continue checking all connections to the stator and test the stator.

 

[Motosportz]

I did just as shown in the vid and all seems fine. Huh. what now? This is just saying the rectifiers is good but the regulator could still be bad in the unit or not? I am an electrical infant.

 

[Motosportz]

off to try and check the stator. Please don't let it be the stator

 

[Micfasto]

Did you take a voltage reading from you battery at rest and running? What were the readings? 12.7-8 at rest 14.5-6 running is what my 310 is at. Yours should be close to the same. Should be higher running if your stator is working right.


That should have been your first test.

If your numbers are close to what I posted than it is the battery.

 

[Motosportz]

Did you take a voltage reading from you battery at rest and running? What were the readings? 12.7-8 at rest 14.5-6 running is what my 310 is at. Yours should be close to the same. Should be higher running if your stator is working right.


That should have been your first test.

If your numbers are close to what I posted than it is the battery.

I have a trail tech voyager and it reads input voltage. I knew the other day something was up because it usually reads about 14.3 when running like it should. It did not, read about 12.3 which was battery voltage only not charging and the more I rode the bike and started it it just keeps dropping. So I knew ether the stator was not putting any power out or the rec/reg was not working or there was a short / bad connection. I replaced the battery and same results. It is always in a state of discharge. There is no change in voltage like there should between not running and running.

- Tested the rectifier as per above vid, tests fine.

- No way to test the regulator part of it. And I hope thats my issue.

- I see voltage changes when I rev the motor but just slightly.

- I just unplugged the stator and tested it directly and it seems to be working but I am unsure what leads i should read what on. I do see voltage and it does increase as i rev the motor. At least 1 or 2 legs are outputting.

Question, can I simply unplug the stators three wires and test each one with the positive volt meter on the leads and the negative to ground? If so should this show 20-50 volts or something each right?

thanks
K

 

[LandofMotards]

So how many miles are you at?

 

[Motosportz]

I think about 4500

 

[Xcuvator]

I have a trail tech voyager and it reads input voltage. I knew the other day something was up because it usually reads about 14.3 when running like it should. It did not, read about 12.3 which was battery voltage only not charging and the more I rode the bike and started it it just keeps dropping. So I knew ether the stator was not putting any power out or the rec/reg was not working or there was a short / bad connection. I replaced the battery and same results. It is always in a state of discharge. There is no change in voltage like there should between not running and running.

- Tested the rectifier as per above vid, tests fine.

- No way to test the regulator part of it. And I hope thats my issue.

- I see voltage changes when I rev the motor but just slightly.

- I just unplugged the stator and tested it directly and it seems to be working but I am unsure what leads i should read what on. I do see voltage and it does increase as i rev the motor. At least 1 or 2 legs are outputting.

Question, can I simply unplug the stators three wires and test each one with the positive volt meter on the leads and the negative to ground? If so should this show 20-50 volts or something each right?

thanks
K

Don't forget that you are measuring AC volts, so you can probe with your meter to the three outputs from the stator. If you are seeing low or irregular readings right of the stator, it sounds like the problem.

 

[Micfasto]

Don't forget that you are measuring AC volts, so you can probe with your meter to the three outputs from the stator. If you are seeing low or irregular readings right of the stator, it sounds like the problem.

Post what you are getting from readings from all the locations. This will help diagnosis it (The AC power from the stator will go up with RPMS but it should be close to the same on all legs.)

The below is from the manual. Pretty much can only be 3 things (my best guess is a faulty plug or wire rubbed though.) You replaced the battery. next step is what is the power going into the rectifier (will vary with RPMs).



Generator does not charge or
is not providing enough charge


1. Cables running to voltage regulator improperly connected or Connect correctly or shorted replace
2. Voltage regulator faulty Replace
3. Generator coil faulty Replace

 

[Motosportz]

thanks all. I will look at the stator again tomorrow.

- Rectifier tests fine as per internet vid. I knew what a rectifier does just did not know how the simple vid was cool and makes perfect sense how it functions.
- Voltage regulator which is integral with the rectifier is unknown. Seems there is no EZ way to test this. Actually hoping it is the problem. Found a used one cheap.
- Stator, like I said need to revisit. I did not know what combo of wires and what to set my multi meter at. Seemed to get readings on all three and they do rise if you increase RPM. One seemed lower than the others but again, not sure I had the right combo going.

Question - Can I put the negative end of the meter on a frame ground and touch all three phases (wires) from the stator loom? Does that work / measure right or no.

 

[James Patton]

If you read voltage from one of the generator leads to ground. That's bad, as the print show it is not grounded.
Best to check voltage from generator (3) leads, 1&2, 2&3, 1&3, should read close to same on all 3 phases. Not sure
what the output should be, I will try mine tomorrow and see what it reads. It's AC out of generator/alternator,
DC after rectifier regulator.

 

[Xcuvator]

thanks all. I will look at the stator again tomorrow.

- Rectifier tests fine as per internet vid. I knew what a rectifier does just did not know how the simple vid was cool and makes perfect sense how it functions.
- Voltage regulator which is integral with the rectifier is unknown. Seems there is no EZ way to test this. Actually hoping it is the problem. Found a used one cheap.
- Stator, like I said need to revisit. I did not know what combo of wires and what to set my multi meter at. Seemed to get readings on all three and they do rise if you increase RPM. One seemed lower than the others but again, not sure I had the right combo going.

Question - Can I put the negative end of the meter on a frame ground and touch all three phases (wires) from the stator loom? Does that work / measure right or no.

You should have nothing that goes to ground. Check your voltage with your meter in the "AC Volts" position and check the three phases back and forth for consistency at a given RPM.

 

[Motosportz]

OK, thanks. I did not ground it. I did do what I think were combos shown above and think one might have been lower then the others but all made voltage and raised with RPM. Will check again and report back. Appreciated.

 

[Motosportz]

Best to check voltage from generator (3) leads, 1&2, 2&3, 1&3, should read close to same on all 3 phases.

did that, will do again.

It's AC out of generator/alternator, DC after rectifier regulator.

Knew that but thanks

 

[Xcuvator]

Hey, you are getting close

 

[268fords]

What! This is weird that your asking the questions Kelly. I haven't read any mention about any possible buildup on the pickup magnet to the stator. I'm no pro, but that came to mind.

 

[Xcuvator]

What! This is weird that your asking the questions Kelly. I haven't read any mention about any possible buildup on the pickup magnet to the stator. I'm no pro, but that came to mind.

Very good point. But first we need to see where to look.

 

[Motosportz]

What! This is weird that your asking the questions Kelly. I haven't read any mention about any possible buildup on the pickup magnet to the stator. I'm no pro, but that came to mind.

It happens. And I know right were top come

 

[Micfasto]

- I just unplugged the stator and tested it directly and it seems to be working but I am unsure what leads i should read what on. I do see voltage and it does increase as i rev the motor. At least 1 or 2 legs are outputting.

Question, can I simply unplug the stators three wires and test each one with the positive volt meter on the leads and the negative to ground? If so should this show 20-50 volts or something each right?

thanks
K

On page M.10 on the 2011 manual it shows a picture of the regulator/rectifier (image 4)looks like 3 yellow wires (these are legs C,D and E) with one brown wire (-) and one pink with white stripe (+). You should take the readings off the yellow wires. C to D, C to E and D to E they should read close to the same.

****(edited to label the legs the same as the video I posted)****



Testing to ground with 3 phase wires does not always work correctly (floating ground) test them to each other.



And while you are in there switch the meter to DC and see what is coming out right at the plug. If you have AC going in (each leg equal) my guess is around 50-70 volts and 14.6 coming out that would mean the stator regulator/rectifier are good.

If you have good AC going in and no or high DC coming out it is your regulator/rectifier.

If you have low or uneven leg to leg AC then it is your stator.


Then there is the big IF; corrosion of a plug/connection you should be able to check that at the same plug on the regulator/rectifier. Check it with your meter in diode mode ->l- with the motor off, like in the first video

A would be your positive wire (the pink with white stripe) B would be your negative wire (brown) and C,D,E would be the yellow wires. (labeled in the video).

Do this testing with the harness plugged in and with the probes stuck in from the back of the plug. This technique will test both the connection of the plug and the function of the regulator/rectifier.

Hope it makes sense.