93 klx-c 650 charging issue: tested all components - Kawasaki KLR 650 Forum
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post #1 of 19 Old 02-09-2019, 01:13 PM Thread Starter
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93 klx-c 650 charging issue: tested all components

my klx isnt charging correctly.
93 or 94 i dont remember. its the black and green one.

its charging almost fully at 1.5k rpms at 14.2/14.3v

when rpms increase it gradually drops to 13.7v/13.8v

this causes my bike to not want to start after a ride.

i tested the regulator, while connected to the bike(unplugged from the stator).

forward bias test shows 0.543 ohms on the three yellow stator wires with no continuity when checked backwards.

same results with reverse bias test.

stator wires do not have continuity with ground and have a resistance rating of .7 between them

while the bike is running all three stator wires put out about 45 acv @ 3k rpms and about 60 acv @ 4/5k rpms

i did a + voltage drop test by testing the outputwire (white wire) of the reg/rec to the +battery terminal and have .07 @5k rpms

i did a - voltage drop test by testing the ground wire (bk/wht) to the - battery terminal and got .1v @ 5k rpms

so as far as i can tell this should all be within spec. i did not have a manual. i am obviously missing something or these reading are not within spec and my understanding of where it should be is off.

is it off? is there something else to check for? any ideas of what to do differntly?

thanks!!!
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post #2 of 19 Old 02-09-2019, 05:52 PM
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From everything that I have just read, your Charging System is operating normally. As the output Amperage goes up due to RPM increase, the Voltage may go down.

As the charged state of a battery comes back Up after being partially dis-charged by the starter motor the voltage will attempt to stabilize. The voltage regulator will attempt to keep slightly over-charging, so 13.7-13.8 volts is usually considered 'good'.

A 12 volt battery is in theory capable of 'generating' 13.2 volts. That is 2.2 volts per cell.

But in reality a flooded cell 12 volt battery will only retain about 12.6-12.8 volts, one hour after charging & an AGM maintenance free battery will retain about 12.8-13.0 volts.
A lithium iron battery may retain nearer the 13.2 volts.

pdwestman
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Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #3 of 19 Old 02-11-2019, 03:14 PM
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BATTERY condition may be an issue, IMHO.

13.7-13.8 volts appear sufficient for charging a battery, to me.

Without gross parasitic circuit loading, battery oughta start the bike after nominal engine run-up.

Modest proposal: Load-test charged battery.
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post #4 of 19 Old 02-12-2019, 09:45 AM
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If battery load-testing confirms a strong battery, one might consider installing a newer MOSFET type regulator. One will have to modify the electrical connections.

This was recently posted on the .net site, https://www.klr650.net/forums/showpo...8&postcount=17

pdwestman
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post #5 of 19 Old 02-12-2019, 10:12 AM
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Another MOSFET regulator installation article, https://www.klrforum.com/1987-2007-w...rrupgrade.html


This was found with the Google Custom Search function on the RH side of screen,
https://www.klrforum.com/gtsearch.ph...laor%20install

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting

Last edited by pdwestman; 02-12-2019 at 10:18 AM. Reason: added info
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post #6 of 19 Old 02-19-2019, 09:35 AM Thread Starter
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Ive been going thru batteries. This is a good agm battery. The voltage shouldnt go down as the engine revs. It is an issue because my bike wont start. Will die when cranking but as soon as the cylinder turns over when i bump start it it fires immediately. Why would they use such a small battery for such a large thumper?
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post #7 of 19 Old 02-19-2019, 09:38 AM Thread Starter
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Why would this charging system work differently then any other chargi g system ive worked on or learned about? Bike should charge at low rpms around 13.5 and at high rpms around 14.5 . And 13.5 is not enough to keep the bike fully charged.
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post #8 of 19 Old 02-19-2019, 11:42 AM
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Quote:
Originally Posted by pdwestman View Post
Another MOSFET regulator installation article, https://www.klrforum.com/1987-2007-w...rrupgrade.html


This was found with the Google Custom Search function on the RH side of screen,
https://www.klrforum.com/gtsearch.ph...laor%20install
Have you read any of the Hi-Lited Links in my eariler postings? I just re-confirmed that all three of them operate.

A TX9 AGM battery in your KLX650 is not necessarily an undersized battery! Same size used in DR650, XR650, VFR750 V four.

The question remains, what is wrong with your bikes starting system and/or charging system?

Did you purchase that battery in a box? Dry / Un-filled & you had to charge it yourself? Or was it 'supposedly' Filled / Charged / Ready to Install from the retailer?
Either way, I have to find it questionable from 12,000 miles away.

Here is my 1st question.
What was its 'at rest' voltage before you ever put it in the bike?

What is its 'at rest' voltage one hour after charging And one hour after riding?
I've found that an AGM should be initially charged to 15.5 VDC on an old fashioned 1 amp charger for Longest/Strongest life.
Automatic Chargers / Battery Tenders / Maintainers usually turn-down Too Early to achieve the 15.5 VDC.
If an AGM is not brought up to this 15.5 volts on its initial charging, they seem to never achieve full strength & die young. Flooded cells need to be brought up to 14.5 volts for the same reason.

A 'Good' AGM should then Maintain at-least an 'at rest - 1 hr after charging' Minimum of 12.8 volts.
Will your battery pass this simple testing today? Will your battery still be very close to the 12.8 volts after 6-12 hours?


Yes, I will agree that if your charging system would maintain nearer 14.2-14.5 @ 2000-7500 rpm it would be better.
Therefore I supplied the links to threads about the new style MOSFET regulators.

pdwestman
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Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #9 of 19 Old 02-19-2019, 12:05 PM Thread Starter
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Why are we talking about filling a battery? I mentioned it was an agm. I did a bench test on my reg/rec and that passed. Off the charger it was at 13+ i dont remember exactly and it noted the voltage drop from a day to three days to a week and it dropped a volt or so. I do have a radio wired into the bike. Possible volt draw, but i did a voltage drop test and everything came up honkey dorey. The bike wont start again after a ride. Sometimes wont start from sitting. If im charging as it should, why am i having these issues. Might have another issue causing the bike to not want to start, draining my battery. Idk alot of factors but ive been trying to eliminate them.
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post #10 of 19 Old 02-19-2019, 12:19 PM
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Yes and I'm trying to eliminate the probability of an improperly prepared & initially charged battery/batteries!

A Good Battery should not drop more than a tenth or two of a volt in a week, unless either IT or the unit it is installed into has issues.

pdwestman
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Still riding my 1987 KL650-A1. 84,000+ miles & counting
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