Forum

[Norm]

Jacob, at the end of the day I usually don't know what way I connect them up, I am usually swapping wires back and forth and I usually give up on the A/C side and run with the best D/C I'm getting at the battery, in fact I think one I ended up only using the yellow/orange wires because when I hooked up the purples the output went down and this was a new stator. Bike is still running and charging fine, another one I set up overcharges all the time so it is always ridden with the lights on to stop it overcharging the battery and it has a powerbox fitted

[JTL]

Oh yes Norm, them bikes works the mysteries ways. Best thing is: they work. At least most of the time... Jacob

[AllyF]

Thanks folks

I've done a couple of journeys of 30 miles with headlights (55/60 watt) on with no problem (running lights etc. are all LED), Powerbox temperature OK, just ever so slightly warm, battery charging ok, battery temperature at ambient.

Strange thing is that the bike's ammeter is 1/4 into the green with the lights off at 60 and switching on the lights see the charge rate jump to 2/3 into the green. I would have thought that it would be less with the lights on.
I've done nothing special - just wired the lights via a relay run from the brake switch, with the main power coming from the red feed to the starter motor solenoid into the yellow. I have used the disconnected amber from the AC reg as the earth.

Quick question on measuring the Vac - what wires do I measure this across - the two going into my Powerbox from the alternator (after the yellow/orange joins?)
Regards Ally F.

[Norm]

Ally not sure what you mean by after the yellow/orange joins but if you mean after the yellow/orange joins the purples then yes this is where to check the A/C volts.I wouldn't get too concerned about what the ammeter does, volts are what is important and as long as you are showing 13+ volts D/C at the battery that is all that matters. Only time to worry about what the ammeter does is if it goes beserk and this will indicate something is wrong

[Thack]

JTL, if you could post your wiring diagram as soon as it's ready it would be tremendously useful for helping pin down any residual problems.

[JTL]

Ally... your set up and readings are very similar to my bike. Curious about your Vac values... Thack, you are now contributing to my not so good consceince. I have only a half finished wire diagram, but the good news is that I have discovered some minor flaws in the wiring. This has of course to be corrected before I can finish the wire diagram; meaning I have some slack on the diagram deadline. Long story short; right now I have no wire diagram to show. Sorry. When it's done I will happily share it with the forum. Actually I have previously suggested Mr H to write a tech note on converting the AC/DC system to pure DC. At Hitchcocks they have the knowledge and skill to do a correct convertion with a detailed wire diagram. As a bonus they can sell us all the different parts needed. Just a thought... regards Jacob

[AllyF]

Sorry to be a numpty.
So to measure the current I measure across the 2 purple leads? Do I disconnect them from the Powerbox - or measure when they are connected? (I'm not very good with AC) "For Gods sake Jim I'm an Engineer (Mechanical)"

Also here is my wiring diagram for my bike:-
https://www.dropbox.com/s/ythttyqobpi8j ... n.jpg?dl=0

Regards Ally F.

[JTL]

Ally... yes, you meassure across the two purple ones. You can do this with only the purple ones or with purples ones connected to to the yellow and the orange (one purple to the yellow and one purple to the orange). To get the combination in phase, you have to choose the yellow/orange to purple connction with the lowest AC reading. Mine was 25,2 Vac at half throttle... Actually I don't know if you have to disconnect the wires from your Powerbox or not to get a correct reading. The ignition will run from the battery so it's ok to disconnect the wires for a short period while meassuring. I believe others know more about this particular subject than I, so you have to get more opinions than just mine... regards Jacob

[AllyF]

Jacob
Many thanks.
I'm out tomorrow so will measure up on Thursday.
Also got to fit a new battery and new fork rubbers.

Thanks Ally F.

[AllyF]

My findings:-

Approx 2,000 rpm

I disconnected the alternator leads from the Powerbox.

Purple to Purple = 30 Vac
Yellow to Orange = 20 Vac

Combinations
Mode 1 ...Purple 1 + Orange to Purple 2 + Yellow = 30 Vac
Mode 2 ...Purple 1 + Yellow to Purple 2 + Orange = 6 Vac (I double checked it)

Back to mode 1

Battery volts (brand new AGM battery)
Ign off = 12.44 Vdc
Idle no lights = 12.41
Idle with lights = 12.10
Fast idle no lights = 12.8
Fast idle with lights = 12.41

Not sure what this all means.

Did 45 miles yesterday, with lights on. Came home and did 3 button starts - all strong, no problem, plenty of juice.

I think that until something happens I'll keep the 30 Vac combination - out of phase or not as 6 Vac seems a bit feeble.
One thought - could the out of phase be nearly 180 degs - i.e. nearly cancelling out the voltage (I did say I know nothing about AC).

Perhaps I am worrying about nothing.

R. Ally F.