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Old 12-08-2005, 04:15 PM   #16
bmwktmbill
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Location: Traveler
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Stefan,
The colors are close but two wires you named have two colors.
Could you go through the testing procedure again for the stator wires for the correct procedure for seeing 12.7 V.
Should the bike be running or not, if not running ignition on or off. Sorry to ask such simple questions but Iam not sure of the answers.
Bill in Tomahawk
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Old 12-09-2005, 01:19 AM   #17
Happe
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Location: Wales UK or Switzerland
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Quote:
Originally Posted by bmwktmbill
Stefan,
The colors are close but two wires you named have two colors.
Could you go through the testing procedure again for the stator wires for the correct procedure for seeing 12.7 V.
Should the bike be running or not, if not running ignition on or off. Sorry to ask such simple questions but Iam not sure of the answers.
Bill in Tomahawk

Hi Brian, Bill, ??

Looks like I'm messing up two electric systems at the same time

Bill,
to measure you have to disconnect the generator and the rectifier.
Will be impossible to start the engine
Also have the ignition off. You just want to measure the single part.
What year and modell is your bike?

Both:
I had a look thru the wiring diagrams and it looks like KTM changed generators over the years

Brian:
Here we go:
There is no extra charging coil in this generator
you should have a yellow, a red/black and a black/red cable
If you now measure
red/black to black/red
red/black to yellow
black/red to yellow
you should read 0.45-0.56 ohms

If you are fiddling around down there, measure the pulser coil too.
Should be a green and a white cable. Should read 80-120ohms.

But I think your problem is in the rectifier. Measure the red to each of the yellow cables. In both directions. In one direction you should read nothing. This will show you if the diodes in the rectifier are ok. They usually block the power in one direction. If you read something in both directions the rectifier is toast.

cheers

Stefan

*7 days to Morocco*
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Old 12-09-2005, 02:44 PM   #18
AllEuro OP
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Location: Oahu
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A Big Mahalo for Stefan

Quote:
Originally Posted by Happe



Hi Brian, Bill, ??

Looks like I'm messing up two electric systems at the same time

Bill,
to measure you have to disconnect the generator and the rectifier.
Will be impossible to start the engine
Also have the ignition off. You just want to measure the single part.
What year and modell is your bike?

Both:
I had a look thru the wiring diagrams and it looks like KTM changed generators over the years

Brian:
Here we go:
There is no extra charging coil in this generator
you should have a yellow, a red/black and a black/red cable
If you now measure
red/black to black/red
red/black to yellow
black/red to yellow
you should read 0.45-0.56 ohms

If you are fiddling around down there, measure the pulser coil too.
Should be a green and a white cable. Should read 80-120ohms.

But I think your problem is in the rectifier. Measure the red to each of the yellow cables. In both directions. In one direction you should read nothing. This will show you if the diodes in the rectifier are ok. They usually block the power in one direction. If you read something in both directions the rectifier is toast.

cheers

Stefan

*7 days to Morocco*

Thanks for the help I will go at it tonight with the new instructions I did the previous check and got no readings in either direction on the rectifier. I think it may be the stator? I will go done to my boat and get my fluke meter and try things out this weekend. All this work on the old ktm made me buy a new 05 TE 450 Husky for a change of pace. Good deal and I'm week for new bikes.
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Old 12-11-2005, 08:11 PM   #19
AllEuro OP
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More test or buy some parts?

Quote:
Originally Posted by Happe



Hi Brian, Bill, ??

Looks like I'm messing up two electric systems at the same time

Bill,
to measure you have to disconnect the generator and the rectifier.
Will be impossible to start the engine
Also have the ignition off. You just want to measure the single part.
What year and modell is your bike?

Both:
I had a look thru the wiring diagrams and it looks like KTM changed generators over the years

Brian:
Here we go:
There is no extra charging coil in this generator
you should have a yellow, a red/black and a black/red cable
If you now measure
red/black to black/red
red/black to yellow
black/red to yellow
you should read 0.45-0.56 ohms

If you are fiddling around down there, measure the pulser coil too.
Should be a green and a white cable. Should read 80-120ohms.

But I think your problem is in the rectifier. Measure the red to each of the yellow cables. In both directions. In one direction you should read nothing. This will show you if the diodes in the rectifier are ok. They usually block the power in one direction. If you read something in both directions the rectifier is toast.

cheers

Stefan

*7 days to Morocco*

Stefan,

I checked the rectifier with my Fluke meter I was using a phony pocket unit until I retreived the Fluke, The rectifier checked out OK with no readings in one direction and all the readings in the other other direction checking out the same.

As for the stator All the readings were different and none near the +/- 20% of .45 ohms. the resitence was higher and all the readings were way off from each other. So I guess I need a stator? I just want to be sure as it is surely a spendy unit. I just paid $300 for one on my Gas Gas that came as a unit with the pick up and ignition unit all as one. Is there any further test before I go see my friendly parts man. I really appreciate the help on this one.

aloha,
Brian
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Old 12-12-2005, 12:38 AM   #20
Happe
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Quote:
Originally Posted by AllEuro
Stefan,

I checked the rectifier with my Fluke meter I was using a phony pocket unit until I retreived the Fluke, The rectifier checked out OK with no readings in one direction and all the readings in the other other direction checking out the same.

As for the stator All the readings were different and none near the +/- 20% of .45 ohms. the resitence was higher and all the readings were way off from each other. So I guess I need a stator? I just want to be sure as it is surely a spendy unit. I just paid $300 for one on my Gas Gas that came as a unit with the pick up and ignition unit all as one. Is there any further test before I go see my friendly parts man. I really appreciate the help on this one.

aloha,
Brian
Hi Brian,

what readings did you get?

cheers

Stefan
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Old 12-12-2005, 08:54 AM   #21
AllEuro OP
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Quote:
Originally Posted by Happe
Hi Brian,

what readings did you get?

cheers

Stefan
I did not write it down and I'm at the job now so I will check it again tonight and reply with the results.

Cheers,
Brian
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Old 12-12-2005, 06:10 PM   #22
bmwktmbill
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Stefan,
My motorcycle is an '02 LC4 640 Adventure model. The wire colors you are using for Brian seem good for my wiring diagram. Are they? Are the ohm values the same for my electrical system?
Bill.
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Old 12-12-2005, 09:52 PM   #23
AllEuro OP
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got the info together

Quote:
Originally Posted by AllEuro
I did not write it down and I'm at the job now so I will check it again tonight and reply with the results.

Cheers,
Brian
Stefan,

I had a yellow, red/black and black/yellow wire on my stator leads

red/black to black/yellow 1.2 Ohms
red/black to yellow 1.6 Ohms
Black/yellow to yellow 1.9 Ohms

I tested all of these in both directions and before I had my second beer. and certify them accurate as the Fluke 87 meter.

The rectifier checked out with no reading between red to yellows with the +(red) lead of the meter hooked to the red wire. with the - (black)lead connected to red all yellows had the same reading 3.1 M ohms.

I'v now had 3 beers and my analysis of the data would suggest my readings on the stator leads are 4 to 5 times the value you gave of .45 to .56 ohms. Does the vote go for a bad stator? Make it to Hawaii and I will take you riding for your help.

Thanks,
Brian
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Old 12-13-2005, 09:09 AM   #24
Happe
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Oddometer: 676
Quote:
Originally Posted by bmwktmbill
Stefan,
My motorcycle is an '02 LC4 640 Adventure model. The wire colors you are using for Brian seem good for my wiring diagram. Are they? Are the ohm values the same for my electrical system?
Bill.

Hi Bill,

yes, its the same as Brians bike.

cheers

Stefan
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Old 12-13-2005, 09:14 AM   #25
Happe
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Location: Wales UK or Switzerland
Oddometer: 676
Quote:
Originally Posted by AllEuro
Stefan,

I had a yellow, red/black and black/yellow wire on my stator leads

red/black to black/yellow 1.2 Ohms
red/black to yellow 1.6 Ohms
Black/yellow to yellow 1.9 Ohms

I tested all of these in both directions and before I had my second beer. and certify them accurate as the Fluke 87 meter.

The rectifier checked out with no reading between red to yellows with the +(red) lead of the meter hooked to the red wire. with the - (black)lead connected to red all yellows had the same reading 3.1 M ohms.

I'v now had 3 beers and my analysis of the data would suggest my readings on the stator leads are 4 to 5 times the value you gave of .45 to .56 ohms. Does the vote go for a bad stator? Make it to Hawaii and I will take you riding for your help.

Thanks,
Brian
Hi Brian,

I still wouldn't pronounce your generator as dead.
Next step would be to get another rectifier to swap it and see if the part you have is working.

The rectifier has also a regulator integrated. I have no idea how to check that thingy without puting another one in the system

Anyone around that might has a spare?

I would like to jet over to Hawaii, but I'm of to the Desert on Friday

cheers

Stefan
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Old 12-13-2005, 07:12 PM   #26
bmwktmbill
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Stefan,
Thank you, I have the wire colors, procedures and values correct now.
Bill.
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Old 01-30-2011, 03:44 PM   #27
TaxMan
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Location: San Francisco, CA
Oddometer: 96
Question

In trying to diagnose a very slowly dying battery, my regulator/rectifier is looking suspicious.

what is the resistance through a healthy regulator/rectifier? I'm getting 3500 ohms through the red wire and i suspect i should be getting an open circuit..

if I need to replace it, can someone point me toward a good source? the OEM runs nearly $180 and i'm pretty sure there has to be something that will do the same job for a lot less $$.

thanks
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Old 01-31-2011, 08:03 AM   #28
meat popsicle
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Quote:
Originally Posted by TaxMan View Post
In trying to diagnose a very slowly dying battery, my regulator/rectifier is looking suspicious.

what is the resistance through a healthy regulator/rectifier? I'm getting 3500 ohms through the red wire and i suspect i should be getting an open circuit..

if I need to replace it, can someone point me toward a good source? the OEM runs nearly $180 and i'm pretty sure there has to be something that will do the same job for a lot less $$.

thanks
Nothing in the index eh?
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Old 01-31-2011, 08:40 AM   #29
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Quote:
Originally Posted by meat popsicle View Post
Nothing in the index eh?
this was the closest thread i could find in the index. broader searches didn't have the data either. most things had to do with changing out the stator and regulator and not diagnosing a slow leak. hoping someone might already have their seat off and can quick check for me.
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Old 01-31-2011, 08:49 AM   #30
gunnerbuck
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Did you go over your wiring to make sure there are no shorts from rub spots where the shielding is missing... Also check the battery when it is unhooked and left to sit for a day or 2 to see if it still loses juice...
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