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Discussion Starter · #1 ·
I am having problems with my charging circuit (will start with a new battery) and after looking through the 3 differnt manuals I have I noticed they all show a CDI in the circuit diagram. Im sure mine is TI, as it does have 2 moduals mounted under the seat.



Does anyone have a diagram they can post, as while the manuals I have are for CX500's (and one CX500/GL500) none of them state the year. I want to be able to check the stator and asociated parts, but its hard without a diagram. Still keeping my fingers crossed its not the stator



Thanks for any help
 

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CDI/TI, it doesnt matter. the charging systems are all the same.



I usually read the voltage across the battery when the motors

running first

I expect to see between 13.8V to 14.5V at all speeds

If I dont', theres a problem .

the tests are quick and easy



Checking the stator:

disconnect the 3 way plug and test on the plug from the stator

you want to see no more than about 1 ohm between any pair of yellows

and megaohms between any yellow and ground

anything in between is suspect

If you wish you can sat the meter to read ACV

and read the voltage between any pair of yellows at tickover

and then at say 4-5 thou

I'd expect to see around 12-15v-ish at tickover and 80-90V -ish

at speed.)



Checking the Rectifier



set a digital meter to diode test

put the red probe on a yellow and the black probe on the Red

I expect to see about 0.5V on the display

repeat for other two yellows



That half of them tested



Now put the red probe on the green and the black on a yellow

and expect ro see about 0.5v

repeat on other yellows



Anything not around 0.5v suggests a diode has failed



the test I described at top is what we do for the regulator test



It probably all takes less time to do than it took me to write this
 

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Discussion Starter · #3 ·
Thanks for the help Reg, just wasnt sure if the colours were the same between the two types. From the quick peek I took today (watching sons new baby for the day, so only had a few seconds I could check before the wife hunted me down lol) it looks like the 3 yellows go to a plug the goes into a modual next to the battery (assume its the regulator modual). Looks like I will have to unmount the modual to get enough clearance to get the yellow wire plug out.



I assume that if I get at least 15V on the yellow sets at idle (all three coils) then the staor is probably good (unfortunatly, I have no working tack on the bike, 3/4 way through building a digital one).



With any luck I will run the tests after work tomorow, and maybe get lucky and find something simple



Thanks again
 

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I wouldnt worry about the actual engine speed, I dont

I doubt theres a hard and fast reading to be adhered to.

Just note the tickover voltage and see it rises significantly

with engine speed.

the 3 way connector between stator and RR is known weak spot

so examine it closely for burning and heat damage.

it needs to have the 3 terminals clean and tight fitting
 

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Discussion Starter · #5 ·
Got it :) if I get a good reading and the stator checks out OK, I will make sure to pollish up the pins and connectors to make sure I have good contact. Im really hoping its a simple fix, as I FINALLY got my dyna's on and have yet to ride it lol
 

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Discussion Starter · #6 ·
Well, got a new battery that is supposed to be a proper replacement for the bike .... yea, OK, too bad the terminal posts are reversed :-( Well, regardless of the $80.00 piss off, at least its brand new and just filled. Checked out the bike after starting it, nope .... 12.8V looks like the charger circuit is screwed somewhere.



Well, its hard to troubleshoot with no diagram, as the only connector I can find that I cant identify what it does is a 6 pin one with 2 Greens one end, 2 Red/Whites the other end, and one Black in the middle (one pin left empty). The only place I see yellows is going into what is probably the regulator/rectifier (3 Greens, 2 yellows, 2 Red/yellow).



These are all on the side of the bike where the battery is. May have to pull the bags and seat to check, but all I can remember being under the seat is two moduals that drive the coils (TI ones I believe).



Will have to start searching the web and find a diagram, as none of the 7 I now have match my bike :-(
 

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Discussion Starter · #7 ·
OK... located the stator connector. Did some tests and think im loosing my mind... checked 4 times to make sure.... here is what I get;



0.8 ohm between each yellow



with endgine running I get about 40VAC on each coil.



Well, sounds good, BUT I get low resistance to ground on ALL 3 yellows :-( All I can think of is the staor coils are intact and working, but must have a short to ground ... but I do get AC from all 3 yellows when referencing the chasis ground (about 28V on idle)



What do you think, is the stator toast ???
 

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Well, sounds good, BUT I get low resistance to ground on ALL 3 yellows :-( All I can think of is the staor coils are intact and working, but must have a short to ground ...



Yes, you've nailed it - the stator is shorted to ground. The resistance to ground should be infinite.
 

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Discussion Starter · #9 ·
Yea, thats what i figured, just surprised it still generates voltage even to ground (probably a winding section).



Well, guess that messes things up big time and now I guess I need to hunt for a new one. Should be a pain in the ass since all the good places and resorces are in the States :-( . Just my luck, everything runs great except a loud bike, finally get new mufflers on and poof :-(



Not sure what to do except try to locate a "100% sure it works" stator (which kind of leaves Ebay out ). Not sure if I can even get any riding in as Im not sure how long the battery will last from charged to dead in the bike. Would have been so much better if it had died near the end of the season, not the very start :-(



Well, if anyone has any idea's or knows of any suppliers I can get a new stator from (hopefully less than twice the cost of my poor bike) it would be greatly appreciated. Looks like I may have to try that tripple bypass a bit sooner than i thought.



Thanks all for the help
 

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Yea, thats what i figured, just surprised it still generates voltage even to ground (probably a winding section).



Well, guess that messes things up big time and now I guess I need to hunt for a new one. Should be a pain in the ass since all the good places and resorces are in the States :-( . Just my luck, everything runs great except a loud bike, finally get new mufflers on and poof :-(



Not sure what to do except try to locate a "100% sure it works" stator (which kind of leaves Ebay out ). Not sure if I can even get any riding in as Im not sure how long the battery will last from charged to dead in the bike. Would have been so much better if it had died near the end of the season, not the very start :-(



Well, if anyone has any idea's or knows of any suppliers I can get a new stator from (hopefully less than twice the cost of my poor bike) it would be greatly appreciated. Looks like I may have to try that tripple bypass a bit sooner than i thought.



Thanks all for the help


RM Stator is in Quebec, it's where I got mine from 2 years ago.



https://www.rmstator.com/en/motorcycles/honda/cx_500_custom_82/stator.htm



Only $120, they shipped super quick. IIRC I used their Ebay store and got free shipping as well.
 

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Discussion Starter · #11 ·
Thanks Abes, I just ordered one and the delivery time is a couple of days. Now that I have that coming just getting together all the things I will need. Have new gaskets from a complete kit I didnt use, just need a water pump one, and then need to locate a timing chain in case mine is worn.



Looks like I will do the triple bypass as well as replace the front tack cover (have a used one I got a year ago since my tack doesnt work, thing the gear is broke). maybe now I can get a working tach too .... if I can ever get that damn fan off lol.
 

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Thanks Abes, I just ordered one and the delivery time is a couple of days. Now that I have that coming just getting together all the things I will need. Have new gaskets from a complete kit I didnt use, just need a water pump one, and then need to locate a timing chain in case mine is worn.



Looks like I will do the triple bypass as well as replace the front tack cover (have a used one I got a year ago since my tack doesnt work, thing the gear is broke). maybe now I can get a working tach too .... if I can ever get that damn fan off lol.




Your water pump cover gasket should be reusable. I've taken a few 28+ year old covers off recently and had no problems.
 

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Discussion Starter · #13 ·
Well thats good to know, as its only been on there just over a year. Got a full set of gaskets but only used the head ones and the water pump one. Was going to do the front tach housing (mine doesnt work, think the worm gear is broken as the tach cable doesnt spin) but just couldnt get the fan off (actally broke 2 pullers trying)



Now that I can see how to get the fan off I will give it another try, just still dont understand how using a bolt will pull it off ? I thought that center bolt threaded into the cam shaft and held the fan on.
 

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The centre hub of the fans is very soft metal.The threads go easy.I have had,in the past,had to make a couple of,"Wooden Chisels" out of some old broom handle and hammer them carefully either side of the fan to get it to pop off after soaking with loads of rust release.



Note:If you convert to an Electric Fan system,



http://globalcxglvtwins.hostingdelivered.com/viewtopic.php?f=7&t=209



You will never have this inconvenience again
 

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Discussion Starter · #15 ·
My plan is just that, put an electric fan on (I had the fan bolt come out and go through my rad last year, when I was 100KM from home. Had to patch the rad with JB welb at a self serve gas station). I did try to get the fan off when I first stripped the bike down for rebuild, as I have a good tack cover with a working worm gear (one on the bike is toast). Problem is, just couldnt get it off (broke two pullers on it and stopped before I wrecked it).



Since I have to yank the engine for required work (stator, timing chain) I am trying to find and purchase a fan I can use on the bike. Only been searching for about a week now, just cant seem to find any that are posted on the forum as good fits. If I can find one I can use a bit more persuation on the fan as if it breaks it wont be a big deal (may just plasma cut the damn thing lol). I was hoping to also get a controler for it from Marshall when he gets it all set :)



Planing on taking tomorow off, as I missed purolator today with what must be my new stator :)
 

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There are plenty of fans to use,



http://cx500forum.com/index.php?/topic/6360-electric-fan-conversions/



I can see no real advantages to using anything but a simple temp sensor either 75 Deg C N/O



http://cgi.ebay.com/KSD301-Temperat...204?pt=LH_DefaultDomain_0&hash=item2a099559b4





or an 80 Deg C N/O



http://cgi.ebay.com/5-pcs-Temperatu...184?pt=LH_DefaultDomain_0&hash=item3a59ba3710



especially when home-made circuits can fail from bad soldering and that the system I have been suing is now in it's 3rd year on one bike and it's 2nd season with my other CX500 and still no problems.



HTH
 

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Discussion Starter · #17 ·
My main problem is finding a fan that will work. I see a lot listed on Ebay (ducati, ZX6r, etc) but none of then show current draw of dimentions. I would like to keep the rad grill, so I guess there isnt much space to work with. The switches are the easy part, and eventually it will be controled via the digital tach im putting in (have a digital temp display on the new tach guts that can signal on/off)



Im still looking around the forum pages for fan modle numbers others have used that fit in behind the grill, then trying to find them on Ebay. I wouldnt mind a new one, but thay are pricey and I sure dont want to get one I cant make fit, or draws too much.
 

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Discussion Starter · #19 ·

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No.The ones I use are these,



http://cgi.ebay.com/ebaymotors/Duca...4025497QQptZMotorcyclesQ5fPartsQ5fAccessories





I think there may have been a model mix up with the poster or maybe Ducati changed the design per year.However the one you linked to may work as well but I can only speak for the ones I use which are super efficient for their size and current draw,or maybe it's the picture angle?




PS

I can leave either of my CX idling on the centre stand ad-infinitum and they will NEVER overeat
 
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