Question about 2002 Yamaha YZF 600 R thunder cat

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I have an 04 thundercat and the charging voltage at the battery is only about 12.2 vdc what voltage should i have coming out of the stator before regulator

Slowly drains battery

Posted by Kenneth Timmons on

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1 Answer

Gregg Mahin

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  • Yamaha Master
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Hi, Kenneth the following is a comprehensive charging system test that is guaranteed to the find issue with your system.
1. Battery Test: The battery needs to be a fully charged and load tested to ensure proper readings, connections need to be clean and tight. If you are not working with a fully charged and functional battery, all other voltage tests will be incorrect. Standing battery Voltage should be 12.5-13.2 DCV.
2. Charging System Voltage Test: Start motorcycle, measure DC volts across the battery terminals you should have a reading of approximately 13.2-15 DC Volts.
3. Check Connections/Wires: Inspect the regulator/stator plug, and check the battery terminals for connection/corrosion. If everything seems to be in order, move on to number 4 below to determine if there's a failed component.
4. Stator Checks/Rotor Check: Each of the following tests isolates the Stator & Rotor. If AC Output test Fails and Resistance Check, and Stator IB Test Pass then Rotor is at fault (Pull Primary covers and inspect rotor for damage).
5. AC Output Check:
Unplug the regulator plug from the stator
Start motorcycle and change Voltmeter to AC volts.
Probe both stator wires with your meter lead.
The motorcycle should be putting out approximately 18-20 ACV per 1,000 rpm. Reading will vary depending on system, check service manual specification
Generic Specs:
22 amp system produces about 19-26 VAC per 1,000 rpm
32 amp system produces about 16-20 VAC per 1,000 rpm
45 amp system produces about 19-26 VAC per 1,000 rpm
Stator Resistance Check:
Switch your multimeter to Ohm x 1 scale.
Probe each stator wires with meter leads and check resistance on the meter.
Resistance should be in the range of 0.1-0.5 Ohms. Reading will vary depending on system, check service manual for specification
Generic Specs:
22 amp system produces about 0.2 to 0.4 ohms
32 amp system produces about 0.1 to 0.2 ohms
45 amp system produces about 0.1 to 0.2 ohms
Stator IB test or Ground Check:
Switch your multimeter to Ohm x 1 scale.
Probe each stator wire with your positive lead on the multimeter and the negative to ground.
There should be no continuity to ground on either wire.
If there is continuity to ground your stator is shorted to ground.
5. Regulator Test: Each of the following tests isolates the regulator only, so if any of these tests fail, the regulator is at fault.
Identifying Wires:
Battery Charge Lead- Wire going from regulator to battery positive.
AC output leads- Wires coming from the Stator to the regulator.
Ground- Wire from Regulator to ground or regulator may be grounded via the physical bolting to chassis.
Regulator Ground Test: Ensure the regulator body is grounded or grounding wire is fastened tightly to a good ground (you should verify this by checking continuity from regulator body to chassis ground).
Fwd/Reverse Bias Test/Diode Test: This check is testing the Diode function to ensure it is regulating the AC current for the stator into DC Current.
Switch multimeter to Diode Scale.
Place your Multimeter positive lead on each AC output wire.
Place your multimeter negative lead on the battery Charge wire.
The meter should read voltage typically around .5 volts.
Next, switch your multimeter leads putting the negative lead on the AC output wires and the Positive lead on the Battery Charge Wire.
The reading should be Infinite.
With your meter on the same setting, place your multimeter positive lead on the regulator ground wire or to the regulator directly, and then place your meter negative lead on the AC output leads.
The meter should read voltage typically around .5 volts.
Next, switch your multimeter leads putting the negative lead on the regulator ground and the Positive lead on the AC output wires.
The reading should be Infinite.
Note: Below is a table to show the readings:
Positive Lead Negative Lead Reading
AC output 1 Battery charge lead Voltage
AC output 2 Battery Charge Lead Voltage
Battery charge lead AC output 1 ?
Battery charge lead AC output 2 ?
Ground AC output 1 Voltage
Ground AC output 2 Voltage
AC output 1 Ground ?
AC output 2 Ground ?
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
http://www.jetav8r.com/Vision/Stator/fault_finding_by_www.electrosport.com.pdf
HOW TO CHECK YOUR CHARGING SYSTEM and CHANGING the STATOR and REGULATOR...
http://www.thundercat.nl/index.php/download/category/2-manuals
OEM parts for Yamaha
YAMAHA YZF600R Owner Manual
YAMAHA YZF600R Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Posted on Feb 20, 2017

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5 Related Answers

Anonymous

  • 5 Answers

SOURCE: 2001 yamaha r6 keeps going dead! Stator,regulator or something?

you need to check for a short if its not that then it could be your altinator or a regulator box

Posted on Jan 07, 2009

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seakish

  • 492 Answers

SOURCE: 97 gixxer 750, will not start. Starts fill with

Your charger should be putting out 13.0-14.5 volts to keep the battery charged. Otherwise its running off the stator sometimes and the battery at other times depleating the battery. The voltage regulator could be bad or the stator could be bad. try swapping the volt regulator first and start from there. Also a battery that has been depleted should be sufficiently recharged before using it again.

Posted on Apr 30, 2009

Anonymous

  • 10 Answers

SOURCE: I replaced my stator on my 1983 650 silver wing interstate

Where did you get the stator?? If not factory... You might want to us a volt meter and measure the resistance. You can find the resistance specs in its honda service manual. Give some more info!!

Posted on Jun 16, 2009

Anonymous

  • 221 Answers

SOURCE: wire connector between stator & voltage reg/rectifier burnt

your voltage/reg. can be tested in a couple different ways check ground res. check res. then revs. bias on diodes you have ac in dc out it sounds like you may have a diode gone bad allowing ac curent to flow causing the wires to get hot

Posted on Jul 31, 2009

Anonymous

  • 66 Answers

SOURCE: my battery is not charging when bike is running (gsxr 600 k6 )

When you put a voltmeter across the battery terminals, you should get >13.5V (typically) with the engine running. 
If less than this then your charging system is faulty and your battery will not charge. 
See this personally authored thread for a diagnostic guide on how to determine whether you have a problem with your stator or Rectifier/Regulator - inlcuding some cold resistance checks you can do on the R/R to determine if it is shorted. 
[url]http://www.triumphrat.net/speed-triple-forum/104504-charging-system-diagnostics-rectifier-regulator-upgrade.html[/url]
It was written initially for Triumphs, but applies to ANY 3-phase motorcycle charging system. 

Posted on Aug 15, 2009

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