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TW200 Technical help
Started by Kringle at 03-11-2010 8:47 PM. Topic has 2 replies.
  
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 03-11-2010, 8:47 PM
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Kringle
Joined on 03-12-2010
So. Cal.
Posts 2
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16V charge voltage and bulbs burning out
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I bought an '89 TW200 mid-January that has been running pretty good except for the fact that the battery became drained after a few rides. At first I thought it meant the battery needed replacement so following some forum advice I read here I bought a new YTZ7-S AGM battery that is smaller than the stock one and used cardboard to make it fit snug. But my new battery also eventually drained and needed to be removed and recharged with my smart charger. I know that motorcycle batteries do not like to be deep cycled so I have subsequently been careful to recharge the battery after each ride while waiting to figure out what is wrong.
I obtained the TW200 service manual and performed the charge system diagnosis. The manual says the charging voltage should be 14-15V at 5000rpm. Now the TW200 has no tachometer so I do not know exactly when 5000rpm is, but hooking up my multimeter's test leads to the battery terminals and then revving the engine I get about 14-15V if I rev a little bit and then 16V (!) if a I rev a bit more (but not too high and nowhere near redline). In the two months I have had the TW200 I have had both headlight bulb filaments burn out, one turn signal filament burn out, and my hi-beam indicator bulb burn out. (Anyone know where to find replacements for the indicator bulbs?) I am guessing it is the 16V that is doing it.
So it is either my magneto or my rectifier/regulator that has drifted out of spec. I suspect it is probably more likely my rectifier unit, but does anyone know a test procedure that lets me be sure? The manual does not say how to test the rectifier.
The TW200 does kickstart and run with the battery completely removed. (The lights flicker, of course.) I am thinking this might be a good option when I take the TW200 on short rides once a week to keep the carb clean while waiting to fix this problem, because I do not want to overcharge the battery, even though I risk burning out more bulbs by riding the bike more. I have read that AGM batteries are especially susceptible to damage if the charge voltage is over 15v so I want to be extra careful to preserve what is left of my poor new AGM battery I have probably already partly toasted.
Thanks for any help you guys can give me.
1989 TW200
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03-12-2010, 7:44 AM
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Fourcycle
 
Joined on 08-01-2007
SE Michigan
Posts 1,229
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Re: 16V charge voltage and bulbs burning out
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A standard lead-acid battery should be charged in the neighborhood of 13.8 to 15 volts. The best charging voltage is also temperature dependent, and most automotive regulators do compensate for temperature, but I don't think the TW's regulator does. The best charging voltage also changes from one type of battery to another, as when going from flooded to AGM to Gell-Cells. You will even find different charging recommendations from one AGM manufacturer to another. In general, flooded are the most robust and that is what the TW's come with to the best of my knowledge.
However, 16 volts is on the high side and your voltage should not increase with RPM's like you are seeing. It should increase a little as the R's climb from idle but then you should see a sharp plateau around 14 to 15 volts, above which the voltage will not rise no mater how high the R's. It seems to me that your regulator is not working. Make sure that your electrical connections are good, no oxides / rust, and that you have a solid ground connection, again with no oxides, which are insulators for electricity. Be aware that the rectifier/regulator can be dumping ~50 or more watts of power, especially if you have a minimalist electrical system that doesn't draw much power or a burnt-out headlight. The regulator/rectifier can get quite hot as a result and should be mounted to the frame, or some sort of heat-sink, if you modified it's location. An overheating rectifier/regulator will not work properly and the heat can cause it to fail permanently.
If your only tool is a hammer
everything looks like a nail.
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03-12-2010, 8:50 AM
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ellwoodjake
Joined on 08-19-2008
canton nc
Posts 69
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Re: 16V charge voltage and bulbs burning out
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I just addressed this same problem with a Kawy KLR. The voltage regulator was bad and overcharging the battery. After reving it to get 16V, you could see the battery bubbling. This dude had also went through 2 batteries. This regulator is over $100 new, but they can be found used on ebay for around 20. That's the path I took.
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Yamaha TW200 Tr... » TW200 Forums » TW200 Technical... » 16V charge voltage and bulbs burning out
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