- How does a relay regulator work for a bike?
- What to do if the relay regulator is broken
- In what cases can you ride a motorcycle without a regulator relay?
Motorcycle equipment is equipped with a large number of mechanisms that must work efficiently and smoothly every day during the motorcycle season. The operation of all systems and components of motorcycle equipment must be regulated so that sooner or later the motorcycle does not fail and does not turn into a pile of metal. For this, there is a certain mechanism called a relay regulator. They are used to ensure that the voltage for the movement of the motorcycle is supplied to a certain level.
What to do if the relay regulator is broken
Sometimes a situation occurs when the relay regulator becomes faulty. In this case, there is no need to panic. It is very important to take certain measures to prevent all motorcycle systems from failing.
First, you urgently need to disconnect this device from the generator and from the battery so that they do not fail. The voltage will be supplied alternately.
The main thing is to pay attention to ensure that the generator does not fail. In this case, the voltage will be supplied from the battery, where there is a possibility that it will begin to boil away and increase in size. The result will be an explosive situation.
The motorcycle regulator relay diagram shows its structure. Thanks to this, you can figure out how to repair it and connect it.
Switching elements.
These include switches (high-low, turns, engine stop, etc.) as well as brake and neutral sensors and the ignition switch. You can easily “ring” them with a tester, finding out which contact group is not working.
Switching also includes the Izh electronic turn signal relay. Its malfunction is visible by the absence of interruption or no voltage supply to the turn signals.
As can be seen from all of the above, the wiring on Izh Planet is without any special secrets or complex elements, all its parts are easily diagnosed and repairs should not cause difficulties.
Issues of selection, diagnostics and replacement of voltage relay regulators
Various malfunctions can occur in relay regulators, which in most cases are manifested by a lack of battery charging current and, on the contrary, an excessive battery charging current. The simplest check of the regulator can be carried out using a voltmeter - just start the engine and let it run for 10-15 minutes at a frequency of 2500-3000 rpm and with the headlights on. Then, without reducing the speed and without turning off the headlights, measure the voltage at the battery terminals - it should be 14.1-14.3 volts (twice as high for 24-volt ones). If the voltage is significantly lower or higher, then this is a reason to check the generator, and if it is in order, replace the regulator.
The replacement should be a relay-regulator of the same type and model that was installed previously. You especially need to pay attention to the order in which the regulator is connected to the on-board network (to which terminals of the generator and other elements), as well as to the supply voltage and currents. Replacement of the part must be carried out according to the instructions; work can only be performed with the engine stopped and the terminal removed from the battery. If all recommendations are followed and the regulator is selected correctly, it will immediately begin to work, ensuring the normal functioning of the electrical system.
Motorcycle electrical repair
Motorcycle service "PRORACING" is a specialized motorcycle service that is equipped with modern diagnostic equipment. We have everything you need to quickly repair electrical equipment of motorcycles of various brands and models.
Main types of work when repairing motorcycle electrics:
Generator G-424
To understand the principle of operation of the generator and relay regulator, a little theory.
Electric generator G-424 is a three-phase machine, with electromagnetic excitation. Generates alternating current. VGB-2A rectifier converts current into direct current. For normal operation of an electric machine, a relay-regulator PP-330 . The job is to regulate the voltage of the motorcycle's on-board network so that it does not exceed 14 volts.
The G-424 generator is not able to work with a discharged battery. To start the engine and increase to 2400 rpm, the motorcycle runs on a battery. Only after this threshold is exceeded does the electric generator operate in self-excitation mode.
Generator G-424 is PROHIBITED to be turned on without load!
Generator circuit G-424: 1 - cover; 2 — oil seal; 3 - rotor; 4 - stator winding; 5 - terminal block; 6 — back cover; 7 — shield assembly; 8 - rectifier block; 9 - fan; 10 — protective casing; 11 - bearing.
Troubleshooting the generator
The method for determining the malfunction was as follows (I tried several methods, since replacing the relay regulator did not help):
Indirect determination of generator performance
This method does not allow you to accurately determine the malfunction of the generator, but it can still be used to determine whether the generator is “dead,” or there is still hope and the cause of the malfunction lies elsewhere.
Disconnect the wire from terminal “Ш” on the generator. And we apply + from the battery to this terminal, bring the wrench to the generator body, it should be magnetic, not much, but it is noticeable. If it is magnetic, then the rotor winding is working properly. Turn it off.
We connect a 12 volt lamp to the “+” terminal on the generator, and the other end of the lamp to ground. And we connect “+” from the battery to the “Ш” terminal. And we turn the engine with the kickstarter, the light should light up. If this happens, then the generator is working.
In my case, the light was on, I changed the relay-regulator, but the battery still did not charge, and when the engine was running, the red battery charge control light did not go out.
Cleaning and testing the generator G 424
- I removed the generator, unscrewed the back cover, pulled out the brushes - the wear was within normal limits, they were checked with a multimeter.
- I unscrewed the rectifier and it “ringed” like diodes, i.e. In one direction the arrow should deviate, I change the polarity, the arrow does not deviate. Those. the diodes are not “broken”, as they should be.
- I rang the stator windings - everything is normal, there is no short circuit to the housing.
Using the probes through the windows for the brushes with a multimeter, the armature rang - “it rang”, there is no short circuit to the generator housing.
Everything is in perfect order, the generator should be in good working order, so I didn’t completely disassemble it. But there is no charge. Therefore, I began to understand the operation of the relay regulator and look for the reason for it.
Battery
The battery in the motorcycle is low-power. The motorcycle does not have a starter, so its task is only to supply voltage to the ignition system and the generator excitation winding during starting. Thanks to the battery, designed for 12 volts, a stable start of the fifth Planet is ensured; up to the third model, the wiring was 6 volt, and the ignition was not always clear.
Possible battery malfunctions:
- - housings, plates, leakage of electrolyte.
- - determined by measurements using a hydrometer.
- - detected by measuring resistance.
- minus not on the body (frame) of the motorcycle - all the electronics will not work.
Old type or check 591.3702-01
This is a very old type of relay; it was installed on “penny” cars, as well as on many rear-wheel drive cars. It has also always been separately mounted on the body, but the check here is slightly different in terms of contacts.
If you take their markings, then there are only two of them - “67” and “15”. The first contact “67” is a minus, as is the relay body itself, but “15” is a plus. The principle of operation is the same, we connect our charger - we start checking, increase the voltage to 14.5V, then look at the lamp. If it turns off well, no, it’s bad, replace it.
There is another “life hack” - if you connect a light bulb, bypassing the regulator relay, to the wires that went to pins 15 and 67, then remove the wire from the positive terminal of the battery - if the engine does not stall, then the generator is “live”.
Wiring diagram Izh planet - 5, how to determine the malfunction
While easily fixing mechanical failures, motorcyclists experience difficulties if the electrics fail. It’s completely in vain, the wiring diagram of the planet Izh 5 is not complicated, it’s easy to figure out.
There is no need to have special stands and equipment for repairs. A minimum knowledge of electrical engineering and a simple avometer (tester) is enough; even often you can get by with just a test lamp.
We will tell you in more detail about the main electrical wiring components and possible malfunctions. Finding a broken wire or damaged insulation is easy (for example, a bad contact always gets hot).
In this case, we look to see if there is a spark at the coil output and at the output at the spark plug contact. Now in detail about the main wiring components of the Izh Planet.
Generator
The heart is the generator (sometimes called a magneto, but they were never used on Izh Planet). Three windings produce alternating current. For excitation, an additional coil is used instead of a permanent magnet. Therefore, it is impossible to jump start a motorcycle with a completely dead or missing battery.
Possible breakdowns in this unit:
Battery
The battery in the motorcycle is low-power. The motorcycle does not have a starter, so its task is only to supply voltage to the ignition system and the generator excitation winding during starting. Thanks to the battery, designed for 12 volts, a stable start of the fifth Planet is ensured; up to the third model, the wiring was 6 volt, and the ignition was not always clear.
Possible battery malfunctions:
- Mechanical damage - housing, plates, leakage of electrolyte.
- Loss of electrolyte density is determined by measurements using a hydrometer.
- The short circuit of the plates in the banks is detected by measuring the resistance.
- Possibly incorrect connection minus not on the body (frame) of the motorcycle - all the electronics will not work.
Ignition system
The ignition chopper is used to ignite a spark at a certain point in the piston stroke. In early modifications of the electrical wiring of Izh Planet 5, contact was mounted, later electronic.
The main malfunctions of this unit:
The ignition coil increases the voltage to several kilovolts so that the discharge can ignite a spark at the spark plug electrodes. The secondary winding is made of a fairly thin wire; most often it burns out. Although a breakdown between the turns or onto the housing is also possible. The same troubles can (but less often) happen to the primary circuit. Everything is revealed using resistance measurements.
Headlight and alarm lamps
Regular incandescent lamps are used; it is not difficult to find a burnt coil.
Switching elements
These include switches (high-low, turns, engine stop, etc.) as well as brake and neutral sensors and the ignition switch. You can easily “ring” them with a tester, finding out which contact group is not working.
As can be seen from all of the above, the wiring on Izh Planet is without any special secrets or complex elements, all its parts are easily diagnosed and repairs should not cause difficulties.
Now we advise you to watch the video, which shows in detail and clearly the assembly of the Izh Planet 5 circuit.
need a relay.
New member
Hi all! The situation is as follows: the second battery has already swollen: sos: most likely the regulator relay has run out. motorcycle: Monster s4 916 2001
maybe someone has it?
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New member
If you remember, it will be mega cool. Otherwise I don’t really want to wait until the end of September.
Hello Vasily with the plow. By the way, we are neighbors, I’m across the road where the sportsmaster is
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Yes, people, remember.
come visit for some tea
Generator stator 281.3701 for IZH motorcycles
The stator is installed on the right half of the engine crankcase and secured with three bolts. The frame is made of special sheet steel. It has 18 tooth-shaped places for winding phase windings. The phase winding is made of one solid wire with a diameter of 0.9 mm and is wound on six teeth. Each tooth has 20 turns of copper wire wound around it. There are six teeth in total on the winding, so 120 turns are wound. There are three such windings. The connection of the windings is made with a star. The terminals of the phase windings are connected to the terminals of the comb.
The generator stator is covered with an aluminum alloy cover. There are special places on the cover and threaded holes where the carbon brush holder is installed. A breaker with a capacitor to produce a spark. Special comb for connecting wires.
How to check PP with a multimeter on a moped?
The relay regulator on a Chinese scooter is checked using a multimeter with a voltmeter function. For this purpose, a simple DT-830 (or equivalent) is usually used. It is better to carry out diagnostics and measurement of output voltage with the device removed.
Verification algorithm:
- You need to unscrew the fairing with the central phase and find on the frame a device with 4 wires: red, green, yellow and white.
- Then start the scooter and check the voltage at idle: measure it between the green and red wires, setting the multimeter to the maximum value of 20 V.
- If the multimeter display shows a figure of 14.6-14.8 V, this is normal. For stabilizers on Chinese mopeds, this is the operating standard voltage. If at idle the multimeter shows a value of 15-16 V, this is a high voltage indicator. This indicates a malfunction of the relay regulator.
- Then you need to check the voltage supplied to the lighting lamps. An alternating voltage is supplied to the central low beam (high beam) lamp, so the multimeter should be switched to the alternating current measurement mode with a parameter of 20 V.
- Next, we measure the voltage between the green and yellow wires (green is the general electrical network of the moped). If the multimeter shows a network voltage of up to 12 V, then the electrical appliances are operating without additional load.
- If at idle this value is 16 V or higher, and with a sharp increase in engine speed it jumps to 25 V, the device does not stabilize the voltage and, therefore, does not work. With such readings, the device must be replaced with a new one.
Using a multimeter, they check the relay regulator on a Chinese scooter
On 4T scooters, the relay regulator is checked using a tester. Typically a mechanical tester is used for these purposes, although there are also electronic models.
In order to take a measurement, you need:
- switch the device to the “KiloOhm” mode and remove the regulator;
- then place the probes on the first pair of terminals (AB). The tester should show a value of no more than 18 kOhm;
- after that, we change the position of the probes on the terminals in the opposite direction (VA) and measure the voltage again - the arrow on the device should show 0;
- then we install the probes on the next pair of terminals (SD) and measure the readings on this pair;
- swap the probes (DS) and measure the indicator again;
- the remaining measurements have no contact and are not checked. The indicator when checking them should be zero.
In this way, regulators are tested on popular Japanese models with small engine volumes from brands such as Honda (Leard, Dio, Tact), Suzuki, Yamaha.
Signs that a check is needed
If the battery on your scooter often runs out, and it is still quite new, this means that there is a problem with the operation of the relay regulator. As practice shows, it burns out quite often. If the device is faulty, the battery stops charging completely and loses its capacity. This means you won’t be able to start the scooter with a button; you’ll have to start it with a kickstarter.
Another characteristic sign of incorrect operation of the device may be the frequent burnout of incandescent light bulbs. They themselves are durable and have a good durability, but are quite sensitive to voltage changes. This happens because the optimal voltage in the scooter network is considered to be 12-13 V. Increasing this value even by 2 V reduces the service life of electronics and components by 2 times.
The greater the deviation from the norm, the greater the likelihood that something will burn out in the scooter. Therefore, when starting the scooter from the starter due to a power surge and a faulty relay, the bulbs usually burn out.
Signs of a malfunctioning regulator are identical for all models of Chinese scooters. They are especially typical for charging relays for scooters of Chinese models with an engine capacity of 50 cc. Therefore, before making a decision to replace something in electronics, testing systems and devices should begin with the relay regulator.
For all models of Chinese scooters, the symptoms of a malfunction of the regulator are identical.
What is a voltage regulator used for?
The relay regulator stabilizes the voltage of the scooter generator at the required level, not allowing it to increase or decrease the value above or below the norm. This prevents on-board voltage surges from going beyond the established limits (depending on the boards this is 12-14 V) and ruining the work of consumers whose service life is designed to be no more than 13 V.
That is, this part takes on the impulses that arise during the operation of the scooter (turning on the headlights, the starter button) and transfers the resulting thermal shock to itself. In this case, all the heat that could settle on the contacts is generated in it and removed through the device.
In addition to stabilizing the voltage, the relay also converts alternating current into direct current, which is necessary for charging the battery.
Moped manufacturers install charging relays with different parameters on scooters and select them individually for each. Depending on the regulator circuit, the connectors also differ. Chinese models usually have 5 terminals (male), while Japanese models have 4.
I had a wonderful motorcycle Zizer 400 -98.
And one day this happened: after riding, I drove to a gas station and filled the tank full. It’s already dark outside, I go to the motorcycle, look at it, my eyes are happy, my emotions are overwhelming. I sit down, press the starter and figs - there’s some kind of crackling noise, the starter doesn’t turn. I called my friend, explained the situation, he said he would come. I'm waiting, sir, I arrived in about 10 minutes. We didn’t think long about it, it was too late to get to the garage 1-2 km away, so we decided to try to start it with a pushrod. It started up with a bang from the pushrod, but the headlight does not light up. I drove without a headlight, fortunately my comrade was driving ahead and had his headlight on.
Video for those interested. (you don't have to watch it :))
It was night outside, I didn’t bother to rack my brains, I stomped home with heavy thoughts. The morning is wiser than the evening. The next day I went to the garage to solve the problem. I started dancing from something simple. We diagnose fuses. I checked. They turned out to be all intact.
I took a photo of the fuse box in the garage.
I decided to start the horse again, and oh mystic horror... the starter spun, then silence. A neighbor in the garage came here, we don’t leave our own people in trouble
