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XR600 Electrickery problem.

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This topic contains 35 replies, has 0 voices, and was last updated by  Mick D 15 years, 5 months ago.

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  • November 8, 2009 at 10:01 pm #97495

    Mick D
    Member

    OK Trippers XR is up and running. WE have a working head light and tail/brake light.
    No power to the horn and the left hand blinker.
    The right hand blinker glows lightly and doesn’t flash,but if you pull the front brake on,the right blinker works like a beauty :S
    If you put the left blinker on,the flasher unit buzzes like it is operating really fast but that is all.
    The regulator/rectifier behind the head light gets to hot to touch if you let the bike idle for very long and the engine will also cut out when the reg/rec gets hot but will start again straight away.
    Anyone got an idea what is going on?

    November 8, 2009 at 10:09 pm #160038

    tim
    Member

    gday mate
    my 98 model xr400 did a similar thing, if i held the wires going internal to the reg/rect in just the right place all was ok, otherwise it would heat up as you say and things just did not operate as they should, purchased a new reg/rect from Ballards (cheapest I could find) and all was well after that
    hope that helps in some way

    November 8, 2009 at 10:40 pm #160048

    Mick D
    Member

    Thanks for that,I am pretty sure we have a spare reg/rec here so I will give that a go.It was the only thing we didn’t replace.

    Exactly what does it do?? Anyone?

    November 8, 2009 at 10:51 pm #160052

    Greg
    Member

    Why did it work until swapped to the other bike than stop, that doesn’t make sense. Maybe wiring hooked up wrong and the heat is because it is shorted to ground or pinched wire, think about it the only difference is being swapped bikes and if it was done probably it should work on that bike shouldn’t it?

    Mick you are a mechanic, you should know that a rectifier converts ac voltage to dc voltage and the headlight is working isn’t it I read

    Check your wiring, keep it simple and cheap first

    TB

    November 8, 2009 at 11:05 pm #160058

    Mick D
    Member

    Trailboss wrote:

    Quote:
    Why did it work until swapped to the other bike than stop, that doesn’t make sense. Maybe wiring hooked up wrong and the heat is because it is shorted to ground or pinched wire, think about it the only difference is being swapped bikes and if it was done probably it should work on that bike shouldn’t it?

    Mick you are a mechanic, you should know that a rectifier converts ac voltage to dc voltage and the headlight is working isn’t it I read

    Check your wiring, keep it simple and cheap first

    TB

    The blinkers weren’t working before the swap out according to Tripper.

    November 8, 2009 at 11:49 pm #160059

    tim
    Member

    Trailboss wrote:

    Quote:
    Why did it work until swapped to the other bike than stop, that doesn’t make sense. Maybe wiring hooked up wrong and the heat is because it is shorted to ground or pinched wire, think about it the only difference is being swapped bikes and if it was done probably it should work on that bike shouldn’t it?

    Mick you are a mechanic, you should know that a rectifier converts ac voltage to dc voltage and the headlight is working isn’t it I read

    Check your wiring, keep it simple and cheap first

    TB

    Bit more of a think about this and if I was you i would check that you have good earth connections first,Not knowing what you have done I agree with TB that you should check the wiring is correct,

    November 8, 2009 at 11:55 pm #160062

    Greg
    Member

    micknmeld wrote:

    Quote:
    Trailboss wrote:

    Quote:
    Why did it work until swapped to the other bike than stop, that doesn’t make sense. Maybe wiring hooked up wrong and the heat is because it is shorted to ground or pinched wire, think about it the only difference is being swapped bikes and if it was done probably it should work on that bike shouldn’t it?

    Mick you are a mechanic, you should know that a rectifier converts ac voltage to dc voltage and the headlight is working isn’t it I read

    Check your wiring, keep it simple and cheap first

    TB

    The blinkers weren’t working before the swap out according to Tripper.

    Can only diagnose to the information given Mick got a wiring diagram and I will sort it for you

    TB

    November 9, 2009 at 12:09 am #160064

    Mick D
    Member

    Yeah I have a clymer manual,but it only has the wiring diagram for the US XR (no blinkers) and the XL.
    It looks like a freaking rats nest behind the head light,any wonder if there is an earth problem. I might get Moose to bring his over and we will just copy the wiring from his?

    November 9, 2009 at 6:00 am #160066

    dennis da menace
    Member

    micko, isnt this a newly painted frame? when i did the DT up, i noticed the reg/rec and other components earthed by their actual body and not an earth wire.

    silly question but…did you scrape the paint off the mounting areas of the frame where all the electrical component touch?

    if the reg/rec earths directly to the frame it might cause a problem like this ;)

    November 9, 2009 at 9:19 am #160136

    Mick D
    Member

    There was only one earth wire that really concerned me in that regard Menace and that was on the coil. Seeing as the bike starts first kick I ruled it out.

    November 9, 2009 at 9:26 am #160154

    Greg
    Member

    micknmeld wrote:

    Quote:
    There was only one earth wire that really concerned me in that regard Menace and that was on the coil. Seeing as the bike starts first kick I ruled it out.

    At this stage I wouldnt rule anything out just clean all the earths Mick

    TB

    November 9, 2009 at 9:46 pm #160039

    tim
    Member

    sitting here at work doing stuff all, so thought i would try and help some more, what model xr600 is it, does it have the combined regulator/ rectifier unit as some of the earlier model diagrams are showing them as separate

    November 9, 2009 at 10:02 pm #160173

    Mick D
    Member

    Yep combined Rec/reg it says on the case. Although the spare one we have says Rec/reg CDI unit?

    November 9, 2009 at 10:17 pm #160053

    Anonymous

    micknmeld wrote:

    Quote:
    Exactly what does it do?? Anyone?

    The regulator part regulates the output voltage at a constant level so the electric’s of the bike can work properly. The supply voltage will likely be higher and not constant. Supply might be 12-15V for example but the output would be regulated to 10V (just an example).

    The rectifier part converts AC to DC like TB mentioned. It uses wave rectification to do this. AC being ‘Alternating current’ follows a ‘sine’ wave form. Wave rectification converts the whole input waveform (both polarities) to one of a constant polarity (DC). This is achieved by reversing one of the polarities of the supply waveform.

    The image I stole below from Wikipedia shows the AC wave form on the left, the rectifier circuit diagram in the middle (the transformer is shown on the left follwed by a number of diodes and a resistor) and the fully rectified wave form on the right.

    Gratz.rectifier.en.png

    This may not help you solve your problem but at least you’ll know what the part in question does giving you a better chance and finding out what’s wrong :)

    November 9, 2009 at 11:26 pm #160040

    tim
    Member

    what’s the year model of the bike??

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