Electric system testing - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 15 Old 02-20-2014, 01:38 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Location: ELIZABETH CITY NC
Posts: 26
Electric system testing

Hello Everyone,

So i just got my 05 KLR 250 running great. I was out riding and i realized that non of my electrical was working. I got a new battery and it was fully charged. I went out riding and within an hour nothing electrical was working. I know my battery is good because it is brand new. This is my second new battery so i know that is out. What can i do to test my bikes electrical system to find out what is wrong? Please put what your trying to say in dummy terms because i am not the best at knowing what things mean. lol. Thank you.
Mauryo is offline  
Sponsored Links
Advertisement
 
post #2 of 15 Old 02-20-2014, 03:50 PM
2nd Gear
 
Join Date: Mar 2011
Location: San Pedro, CA
Posts: 129
When you say nothing electrical was working does that include the ignition?
Trundlebike is offline  
post #3 of 15 Old 02-20-2014, 04:54 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Location: ELIZABETH CITY NC
Posts: 26
The ignition is just a kick start no electric start. The bike runs and purs like a champ. Its almost like the battery isnt getting recharged.
Mauryo is offline  
 
post #4 of 15 Old 02-20-2014, 06:11 PM
2nd Gear
 
Join Date: Mar 2011
Location: San Pedro, CA
Posts: 129
Sounds like that to me too. An easy way to check charging is to hook a voltage/ohm meter to the battery, start the bike and when you rev it up you should see an increase in voltage from ~ 13.5v up to as much as 14.5v. I use one of these: http://www.harborfreight.com/catalog...tage+ohm+meter
It's cheap and accurate enough for this sort of thing.
Trundlebike is offline  
post #5 of 15 Old 02-20-2014, 06:15 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,256
The KLR250 (like the Generation 1 KLR650) has an ignition circuit separate from the battery circuit.

From your previous post, I assume you find your battery dead after a short operational life.

A simple test of the battery charging circuit, seems to me: Start bike. Connect voltmeter to battery terminals; note voltage. Increase engine rpm; note voltage. You should see a higher voltage at higher rpm.

At higher rpm, you should see about 14 volts DC.

If nominal voltage does not appear, check charging system connections. Still not enough juice? Could be faulty stator and/or rectifier/regulator. Tests and diagnostic procedures may be beyond the scope of a website post, but . . . some information can be found in the Clymer Generation 1 KLR650 service manual, or the Kawasaki KLR600 service manual.

EDIT: Posted before I read Post # 4 above.

Last edited by Damocles; 02-20-2014 at 06:18 PM.
Damocles is offline  
post #6 of 15 Old 02-20-2014, 06:37 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Location: ELIZABETH CITY NC
Posts: 26
ok guys so i just fired up the bike. no matter what rpm i am at the volts stay around 12.something. no jump. i put a new rectifier/stator when i rebuilt the engine. i did all internals. So i'm guessing i need a new rectifier/exciter?
Mauryo is offline  
post #7 of 15 Old 02-20-2014, 06:54 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Location: ELIZABETH CITY NC
Posts: 26
ok guys so i just started the bike and put the voltmeter on it. i had it running with the exciter plugged in and not plugged in nothing happened. it ran the exact same. i am guessing that is what i need. What do you think?
Mauryo is offline  
post #8 of 15 Old 02-20-2014, 07:31 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,256
Your nomenclature confuses me somewhat, Mauryo!

Unless you have operational exciter coils on your stator, it ain't gonna run. Thus, when you say, "i had it running with the exciter plugged in and not plugged in nothing happened," I'm confused. BTW, The exciter voltage (AC) has no effect on the battery charging voltage.

You say you put in a new "rectifier/stator," not sure what that might be. A "rectifier/regulator" exists, but . . . the stator stands alone.

Maybe you could look at an exploded parts diagram fiche and parts list (e.g., from Bike Bandit, etc.) and identify the parts to which you refer in standard terms.
Damocles is offline  
post #9 of 15 Old 02-20-2014, 08:32 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Location: ELIZABETH CITY NC
Posts: 26
Quote:
Originally Posted by Damocles View Post
Your nomenclature confuses me somewhat, Mauryo!

Unless you have operational exciter coils on your stator, it ain't gonna run. Thus, when you say, "i had it running with the exciter plugged in and not plugged in nothing happened," I'm confused. BTW, The exciter voltage (AC) has no effect on the battery charging voltage.

You say you put in a new "rectifier/stator," not sure what that might be. A "rectifier/regulator" exists, but . . . the stator stands alone.

Maybe you could look at an exploded parts diagram fiche and parts list (e.g., from Bike Bandit, etc.) and identify the parts to which you refer in standard terms.
Sorry. I replaced the circle thing in the left side of the engine i think it is called the magneto. The other part i was plugging and unplugging and nothing happened was the piece where you open up the air box on the right side of the bike. square metal thing with a 6 prong plug that only uses 5. I know i sound like an idiot right now but i'm not the best explaining things. this is what i ordered that i was playing with and nothing was happening. http://www.ebay.com/itm/280884124611...S:3160&vxp=mtr
Mauryo is offline  
post #10 of 15 Old 02-21-2014, 04:22 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,256
Bad/improper connection, bad stator (round thing about the flywheel), or bad regulator/rectifier (the part shown in the link above).

Two YELLOW wires come out of your stator; when the engine runs, you should see ALTERNATING CURRENT between these two.

A WHITE and a YELLOW/BLACK wire come out of your regulator/rectifier; you should see 12-14 VDC between these two, when the engine runs (regulator/rectifier must be connected to the stator for this test).

That's about it, for the charging circuit on a KLR250, AFAIK. Since your engine runs, your exciter coils and ignition circuit seem o.k.

Most likely problem, IMHO: broken/shorted stator winding. Using the OHM setting with a multimeter, you can check the two yellow wires for continuity/isolation-from-ground.

If none of this makes sense, might call in someone with some electrical experience, or take the bike to a competent shop. Not trying to put you down or blow you off, but . . . since we can't see the little electrons, it's hard to explain electrical components and their functions in a few words. Best of luck!
Damocles is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Testing andyourdone The Off Topic Lounge 13 12-23-2011 05:06 PM
Testing... Aron31 Show Off Your Bike 20 05-06-2011 12:34 PM
Need help with KLR650 - electric system HKforte KLR & Other Motorcycle Related Discussion 5 03-24-2009 04:11 AM
testing Daddyjoe Introductions 0 10-21-2008 10:00 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome