XS650 Brat Build Ep 20, Charging System Fault Diagnosis

[@Bikesbybruce]

Your clear explanation and multimeter readings are exactly what I needed to get a '78 XS properly sorted. The manuals are good but you brought the subject to life. Many Thanks for taking the time to document and present this information.

[@2wheelworkshop]

No worries mate. Thank you for the feedback. I really appreciate it.

[@mk1cortinatony395]

Great video. iwas just reading the manual today and then found this. 👍

[@2wheelworkshop]

Thanks mate

[@vulcanpie]

Fantastic job. I was able to follow it well and understand what I need to check. Thank you.

[@2wheelworkshop]

Thanks mate. I appreciate the feedback.

[@ForestCounter]

Someone may already have mentioned it, but these videos are brilliant. Thanks!

[@2wheelworkshop]

Thanks mate. Much appreciated.

[@richiebainbridge2608]

Very clear in-depth video thanks. Where were you when I needed you last year lol. I ended up with pma full sparks and charging unit and it great. Cheers from uk.

[@Tater-]

Shed looks amazing now! Vid is on point as usual!

[@chrisracer4094]

Great Video as usual! Nice shop updates!!! thanks for the video !@

[@chrisracer4094]

@@2wheelworkshop man no stress! your videos are great, and I am appreciate you post them.

[@juscozcustoms]

was just thinking the other day that you where about due for another update on the 650. shed is looking great and if you use the old stater it is fairly easy to get to to swap out later if it goes bad again

[@juscozcustoms]

yeah @@2wheelworkshop i understand. if i don't force myself to build something or get a video out every week then suddenly a month has passed without building anything and no videos and it is hard to get back in the swing of things. but your workshop is looking great because of the time out (any chance of a workshop build video?)

[@gerardogonzalez1312]

I just purchased a 1980 xs650 sent the engine to be rebuilt just because I have little time to work on that but as I was going through the wiring my headlight won't come on? It works because when the engine is running I can jump a wire from the battery to the yellow wire on the safety relay and it turns on and stays on but if I don't jump it I don't have volts from the yellow wire from the stator to the safety relay and neither of the 3 white wires coming from the alternator show voltage while running...the stator and rotor are new they were installed.by the previous owner?

[@2wheelworkshop]

The yellow wire from the stator is unrectified and unregulated and it's only purpose is to open the safety relay and prevent the starter from being engaged while the engine is running. Your lights should have nothing to do with that circuit. I think the later models had lighting relays, which yours would be, but without looking at it I wouldn't be able to tell you anything about it.

[@2wheelworkshop]

Make sure your multimeter is set to volts ac when testing the 3 phase wires and the yellow. If it is set to dc it will read zero.

[@gerardogonzalez1312]

Thanks yes my model has the safety relay with two circuits so once the engine is running and the alternator starts charging it sends volts through the yellow wire to the safety relay which shuts off the starter circuit and closes the headlight circuit.....I'm going to do away with all that extra crap and simplify the wiring but if it's not working due to the charging circuit i would like to figure it out

[@steb5608]

Great video! Very concise! Late to the party here but I just bought a 1977 xs650 for a bobber build. Currently going through the charging system and was wondering how you went about cleaning the stator?

[@drufunk]

My 77 isn't charging well. I haven't done all the tests but I did buy an XSCharge PMA kit from Mike's XS. Would you recommend putting that on or actually finding the problem and staying with the original charging system, replacing what's faulty?

[@2wheelworkshop]

If you already have the pma system then I would go with that. I would still try to diagnose the problem for curiosities sake though.

[@azurplex]

Clean those rotor brush tracks and use new brushes, that will help. My guess is carbon dust build up from the brushes created a path for electricity to ground (or between the brush tracks) when dirty, but lack of crud touching it makes it meter as good. One other possibility is a crack or gap in insulation somewhere allowed a short to develop through dirt or carbon buildup and cleaning removed the conductive path. Either means if it gets dirty again, the problem could return, or perhaps regular maintenance will keep that gremlin at bay. It may be possible to re-varnish the coils and seal whatever gap may be there.

[@2wheelworkshop]

Already done mate. Thanks. I reckon it was a gap in insulation in the stator as it failed the bench test initially but after cleaning it passed. It's got some miles on it now and hasn't played up but I am keeping a close eye on it.

[@guypigache2105]

Cracking explanation. Sadly I think the old separate reg / rec is dinosaur tech. A modern reg/ rec and a lithium battery seems to be the way to go. That of course still raises the question of OEM TCI ignition. Only halfway through my rebuild on this stuff.

[@Oatmeal_TVx]

I’d like a diagram on that

[@guypigache2105]

@@Oatmeal_TVx Mine is an XS750 now with a 277 rephased crank by Smedspeed (UK). Used a Ricks Regulator 14-504. AntiGravity Li-Ion battery, plus electronic ignition from Smedspeed. Not sure how to attach my hand drawn wiring diagram.

[@rakistangel]

nice vid again! did you manage to use the new regulator combined rectifier with a '77 alternator?