Need Help with charging system
 

I've been working on my 2000 DS650 that has a charging problem, it will run until the cooling fan comes on and eventually drains the battery.

Here is what I have found/done:

1- Initial start up 14.6 volts & 4.65 amps approx.
2- With engine cold or warmed up if I jumper the cooling fan to run voltage drops to 14.3 volts (which is good) but when I rev the engine up and down the charging will stop within a few cycles of revving, voltage drops to battery voltage (11.8-12.2 volts) and 3 amps, machine will keep running until voltage is too low for ignition
3- If engine is shut off or the connection with the 3 yellow wires from the stator where it plugs into voltage regulator are unplugged for a few seconds and either restarted or reconnected and restarted with the fan off voltage will be back to 14.6 volts until fan is turned on again and engine is reved.
4- when running in the no-charge condition the stator is putting out 18+ volts and goes up with reving engine.
5- battery is new
6- voltage regulator is a new Procom unit, I replaced the factory regulator when I had the initial charging problem because voltage output was erratic and peaking at over 16 volts
7-all fuses are okay
8-all ground wires tested okay, and I also tried running it with a ground directly from battery to the engine and it made no difference
9-wiring looks good everywhere
10-stator continuity tested okay (.3 to .5 ohms)
11-stator insulation tested okay
12-stator dynamic test seems okay, running around 18 to 24 volts ac depending on idle rpm, voltage goes up with rpm increase but is a little erratic, all three phases have same output
13-trigger coil tested okay (275 ohms)
14-I thought maybe the cooling fan is bad and pulling too many amps so I disconnected it and hooked up a good LTZ400 cooling fan which made no difference, had same problem, so I'm confident the cooling fan is okay
15-I think the new Procom regulator may be bad but not sure and a new Bombardier rectified is $140, I live in a small town and nobody owns a DS650, if they did I would borrow their regulator and see if it worked

Any help will be appreciated.

Need Help with charging system
 

do you have a schematic to follow? if so maybe share it so ppl can help you go through it.

Need Help with charging system
 

Don't have a schematic, but I have a service manual, that is how I performed all the tests. Why I am not sure if its the voltage regulator is because of it working sometimes, nobody seems to have an answer as to why. Thanks!

Need Help with charging system
 

TRY GROUNDING THE MOTOR WITH BATTERY CABLES DIRECTLY TO THE BATTERY WITH JUMPER CABLES AND SEE WHAT HAPPENS AND 4.ANYTHING IS NOT ENOUGH AMPS TO MAINTAIN YOUR BATTERY.

Need Help with charging system
 

As I noted I did try running a ground directly to the engine (I don't blame you for not reading it all, it is awfully long, but complete) it made no difference. How many amps should be going to the battery?

Need Help with charging system
 

[img]i/expressions/face-icon-small-blush.gif[/img] You caught me i did not read it all but i can tell you it is not always easy to get a gooood ground to the motor and what your detailing here is a weak ground.some times an electrical system can charge just fine under a small draw but once you apply a steady heavy load it will heat the bad grounding area up and loose continuity and that is how most elec fire acure.but i will run out and test a good charging system right now and give you some charging spec's amperage wise. be back soon.-well im back my wifes 05 baja x at idle puts out 7.6amps and ith the lioghts all on7.9 and 9.7amps at 5000 rpms do you mind me asking what type of meter your doing your ampreage testing with.and there is also a system ground somewhere i cant rember where it is stock because all my bikes are modded but check that too.your cdi is only blown by a grounding issue.but i have seen then go out naturaly but this sounds suspecious.i will go back and read better now.

Need Help with charging system
 

az...u sure have your hands full..i think i will stay in this post and see...i have the same problem as u know...i cant find anything...

az can u give us( really me) a description of were to find all these plugs...i feel like its coming from my high beam aux lights..

Need Help with charging system
 

THOSE LIGTS ARE VERY EASY TO ELIMINATE THEY UNPLUG RIGHT BEHIND THE LIGHTS THEM SELFS JUST UNPLUG THEM AND SEE WHAT YOU READ THEN I HAVE HEARD OF THEM HAVING AMPERAGE PROBLEMS BY DRAWING TOO MUCH I TOOK THEM OFF MY BIKE BUT MY WIFE STILL RUNS HERS AND HAS NO PROBLEMS.

Need Help with charging system
 

each aux light has its own plug?

i found the main headlight plug ...i assume they r different

Need Help with charging system
 

YES THEY EACH HAVE THERE OWN PLUG AND ITS RIGHT BEHIND THE LIGHT THEMSELFS.VERY EASY TO ELIMINATE.JUST UNPLUG THEM BOTH.

Need Help with charging system
 

are they plugs just like the main light and what am i looking for again when i unplug them...im gonna do this tom

Need Help with charging system
 

THERE JUST LITTLE PIGTAIL PLUGS.THERE EASY TO SEE WHEN YOU LOOK BEHIND THE AUX.LIGHTS AND WHAT YOU WANT TO SEE AFTER YOU UNPLUG THEM IS THE BIKE KEEPS ITS CHARGE RATE ABOVE12.9 VOLTS WITH BOTH FAN AND THE MAIN HEAD LIGHT ON AT PROPER IDLE SPEEDS AND MIN 13.2 AT 3000 RPM'S THESE ARE MINAMAL READINGS FOR THE BIKE TO MAINTAIN A GOOD CHARGE.FOR INSTANCE I JUST WENT OUT AND STARTED MY WIFES BIKE THE BATTERY WAS ONLY 12.1 WITH OUT IT RUNNING I STARTED IT IT WENT TO 13.7 AT IDLE AND 14.7 @ 2000 RPM THEN WENT STEADILY DOWN UNTIL THE BATTERY SETTLED AT 13.7 FULL CHARGE.

Need Help with charging system
 

NOW AFTER READING THE POST COMPLETELY THESE THINGS. COME TO MIND AUTOBROKER FIRST PRO COM I HAVE NO FAITH IN THEM.SECOUND ITS OBVIUOSLY LOSING THE EXCITER VOLTAGE WHETHER OR NOT ITS THE PROCOMS FAULT OR A GROUND FRICTION PROBLEM.IM IN THE DARK ON THAT YOU SAY YOU TESTED THE GROUNDS HOW DID YOU DO THAT???.THIRD YOU SEEM TO HAVE A FIRM GRASP ON TROULBE SHOOTING AND THE FIRST TWO IDEAS WOULD BE NEXT IN THAT CASE AND WERE YOU USING MECHANIC GRADE CALES OR THE TRASH THEY SELL IN CHEAP AUTO PARTS STORES. PRESSED COPPER BATTERY CABLES I WOULD NEVER USE ANY CABLES UNDER #4'S WITH A CLAMP THAT WILL DANG NEAR CUT YOUR FINGER OFF IF YOU CLAMPED IT ON ONE.I DON'T KNOW HOW MANY CUSTOMERS CALL ME AND TELL ME I TRIED JUMPING IT AND IT STILL WON'T START. AND I GET THERE AND THERE USING TRASH CABLES THE FIRST THING I DO IS TAKE THEM AND THROW THEM IN THE GARADGE OR AT LEAST AS FAR AS I CAN TAKE A BRAND NEW SET OF # 4 CABLES OUT OF ONE OF MY SIDE BOXES.JUMP THERE MACHINE AND GIVE THEM A BILL THAT INCLUDES THERE NEW CABLES AND TELL THEM NEVER TO CALL ME AGAIN UNLESS THIER USING THOSE CABLES. AND IT WONT START MY PERSONAL CABLES ARE 1.0 WELDING CABLE WITH BALLCAMP ALIGATOR CLANPS THEY ARE 25' LONG AND WILL OUT JUMP ANY CHECKER OR AUTO ZONE THAT ARE ONLY 8' LONG.SIZE MATTERS IN VOLTAGE AND CONTINUITY.[img]i/expressions/face-icon-small-happy.gif[/img]

Need Help with charging system
 

ok so start bike ..take reading...then unplug them and watch volt meter....then what?...im getting confused

Need Help with charging system
 

YES START THE BIKE TAKE YOUR READING .THEN TURN ON ALL LIGHTS SEE WHAT YOUR READING IS THEN.THEN UNPLUG THE AUX LIGHTS AND TAKE A READING THEN. THE PLUG BEHIND THE AUX LIGHTS IS JUST A BULLET PLUG. YOU JUST PULL ON BOTH SIDES IT COMES APART.

Need Help with charging system
 

ok here is what i got.....quad off.....12.8
quad on...14.78 idle
2000 rpms...16.50 and climbing
low beams...14,70
high beams...14.67....my aux lights wont come on for some reason...they havent been coming on when high beam r on until like 10 in later...has to be them...once the come on i will take a reading and try to un plug them...BY THE WAY ITS FREEZING OUT IN THE GARAGE ...29 DEGREES......BBBRRRR

Need Help with charging system
 

MORE...AUX LIGHTS STILL NOT COMING ON...
run 15 min....idle...12.70
fan kicked on....12.37
lights/fan....12.19 and fading
no light/fan...rev to 2000 rpm....volts drop ...

az tried to call you but cell was not taking incoming voice

Need Help with charging system
 

I MUST HAVE BEEN ON THE PHONE I WAS ON IT ALL DAY BUT IM HERE NOW IM GOING TO TAKE A SHOWER JUST GOT OFF WORK.!!!!!

Need Help with charging system
 

Sorry AZ, I been away from my computer for a few days, I do appreciate all the help. In response to the last questions you asked me: I've also had someone tell me that Procom is "junk". My multi-meter is a digital Craftsmen, about two years old was around $120. To test if grounds are good I took the positive lead from the multi-meter and hooked in to the positive battery terminal and then with the negative I hooked it to the different frame and engine grounds, when I did this I got the same voltage as the battery has (engine was off during test) which indicates a connection to ground, doesn't it? When I did the test with a cable direct from battery to engine I used mid-grade jumper cables in new condition and they have strong jaws and please remember I have the same problems when the engine is cold or hot, it makes no difference. I know this because after initial start up I can jumper the cooling fan to run and have the problem (voltage/charging drop). Does anyone make a voltage regulator besides Procom or Bombardier for the 2000 DS? When you ground the battery to the engine just exactly where on the engine do you place the ground?

Need Help with charging system
 

OK CRAFTSMAN MAKES A GOOD METER BUT YOU SHOULD NEVER TRY TAKING AMP READINGS WITH OUT A DC CLAMP ON METER IF YOURS IS A CLAMP ON YOU HAVE A TRUE READING ASLO YOU MUST ISOLATE THE WIRE YOU ARE TAKING YOUR READING AND MAKE SURE THE JAWS OF THE METER ARE NOT TOUCHING ANYTHING ELSE OR THE SAME DISTANCE OF THE WIRE YOU TESTING FROMA ANOTHER WIRE BECAUSE ITS A FIELD TEST.AND FIELD INTERFERANCE WILL INTERRUPT YOUR READING.SECOUND THE BOMB IS THE BEST FOR STOCK FORM BIKES IT IS NOT JUNK LIKE SOME BELIVE IT IS A GOOD REGULATOR RECTIFIER.I HAVE USED ONE OFF A ONAN CCKB BEFORE OR A KOHLER MAGNUM BOTH THESE CAN BE MODIFIED TO USE AND PUT OUT TWICE THE AMPS WITHOUT OVER WORKING THE STATOR.AND I TELL EVERY ONE TO CLEAND OFF THE PAINT ON THERE MOTOR AND GROUND THERE I HAVE A LITTLE UGLY SPOT ON ALL MY MOTOR I THROUGHLY SAND A SPOT ON THE CASES AND PUT A SOLID GROUND ON ALL MY DS'S.

Need Help with charging system
 

CHRIS CHHRIS OH CHRIS CALL TODAY ILL BE IN THE SHOP IN HALF AN HOUR !!!!!!!!!!