Restoring The Electrical System On A 45 Year Old Motorcycle (Part 1/2)
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- Опубликовано: 18 июл 2023
- Most of the electrical components on this Kawasaki KM100 enduro bike are inoperable. We work to figure out what the problems are and how to fix them. This is a 1978 model, but this type of electrical system is typical of many motorcycles of its era. It is a 6 volt battery system with alternator / rectifier charging scheme and lights / turn signals /horn.
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This day just turned into an awesome one
Headlight is part of the AC system. It has to be there or the voltage will run wild. It's a split system. Brakes, taillights and turn signals are on the DC side of the rectifier, headlight AC. Running without a headlight could cause damage. Horn is also DC.
Also the tail light could be hooked up backwards, low for normal and bright for brakes
With dimming of the taillight when turn signals are turned on, I would check for a ground wire issue.
@@BTimmer Probably a good idea, but like he said the turn signals are probably 12v, taking too much voltage from the sytem
when you said the alternator is represented by a "triangle with a line" in the diagram you made me giggle a bit.
it shows the single electrical component making up the "rectifier": a diode!
a single diode is the most primitive type of rectifier possible, since a diode only allows current to pass through one way it essentially cuts the output of the alternator in half by eliminating the negative half of the sine wave.
it "transforms" the generator output into a pulsating dc current and works as a primitive rectifier (but loses half of the power in the process)
also, i would suggest you take a look at wago connectors (or similar) for connecting wires - the American wire nuts are prone to errors because you can't actually see if they make a proper connection and their performance is meh.
edit: I studied electrical engineering, shoulda probably led with that
Really love your videos I always look forward to them!
Yes!!! A new video! I hit the like button before even starting to watch. That's how confident I am in watching you two. 😎
I could watch you two wash dishes together.. You seem totally COMPATIBLE !!! More vids , please ..
Thank you so much for still making videos. You guys and ave are my favorite RUclipsrs right now ❤
I could watch your videos all day - I've done that before. You have a real skill for it and I hope you continue to make more!
Fancy seeing you here
I just rewatched your klr250 series the other day
Thank you sir!! I appreciate it.
Great wee bike, I had a Kawasaki KV100 when I was in my mid teens. I went everywhere on it and once tried to travel 140 miles on it, needless to say I never made it and had to get my father to pick me up. I even had a workshop manual with it and that showed how to port it and how to modify the rotary valve. Your bike is bringing back so many memories.
Can't even express the excitement I receive when you guys upload! Love the videos!
My first bike was a KD80, same frame but smaller engine and no street equipment. Still have it, great machine 👍
Been a subscriber for years now. Absolutely love watching the videos when they come out. Always something to learn from you. Thank you
Jake and Jenny are the most wholesome family on RUclips. Thanks for the videos and God Bless you and your family. 🙂
Jennie’s Garage always brings Smiles
Jake, can’t thank you enough for all you have inadvertently taught me about motorcycle electrical systems. I have diagnosed electrical problems on at least 8 motorcycles (including 3 Honda trails) since I started watching your videos back in 2014-2015. Keep up the good work, hope you are doing well. Edit:I miss the new balances
Blessed again! Love it when you guys upload thank you.
I'm curious, what ever happened to the trail bike? It was the build that drew me to your channel initially. Glad to see you guys still pumping out videos. 👍
I really liked this video. The way you were trouble shooting made a lot of sense. Thanks!
One of my top channels that i don't ever want to be without.
I also have klr style turn signals that can take 6v bulbs and have the correct skinny connectors for the turn signals
Lovely to see you both, enjoyed the video. 🇦🇺🦘
Always glad to see a new video! Even better when it's not long after the last one
If you need a picture of the wiring diagram, I have the clymer manual and I can send you a picture of it. If you need any other specs, let me know.
I really love your videos man. Keep up the good work. Greetings from the netherlands🇳🇱🇳🇱
Nice Bike, The 70's Was A Awesome Time To Grow Up. I Love Leaning New Stuff.
Glad you enjoyed it! I hope to get the little bike fixed up.
Love watching you fixing to things.
Great video
Keep em coming.
Excited to see another video from you guys, hi from the UK 😉
I have watched about 90% of your videos but honestly I think this is my favorite. I really enjoyed watching you troubleshoot this.
Thank you!
Among other reasons, this is the main reason I subbed. Thanks for sharing.
I learn so much from hese videos. Thank you :)
Wow now your spoiling us 😊 2 uploads in a year .
Another great video guys.
😀 a new project….awesome let’s get stuck in , love watching these guys 👍
Booth of you never fail to entertain me, thx for sharing....
I’m 45 years old, and I’ve been altered with. No truer words spoken.
Love the video. Those videos are why I am following the channel. Please more ❤
Yay! Love you guys and your content!
Excellent work Sir
Thank you!
Was just watching the Husqvarna TE250 video's and saw you uploaded again, love watching your video's. Specially while eating a pizza! :) Hope you and you family are doing well, have a nice day!
Thanks! I'm glad you like the videos. Have a good one!
The best nest talk going. Thanks for another awesome video (despite the absence of Marbles.)
Keep these videos coming. Love watching you guys tinker
Geez I haven't heard from you guy's in ages, great to see another video from you and see you again! I had that exact bike myself! You've got the alternator connected wrong, it's severely over charging, isn't there a regulator somewhere in that mess?
You guys are so much fun
Good video.
Nice detective work!
Very nice video ❤
Thank you!
Thanks for vid!
18:00 you had the multimeter set on 200. It should be on 20.
Another treat so soon? Yeah!
Very clever idea searching ebay for weird parts; I'll keep that in the bag of tricks. Also clever of camera girl to know about gas in the carb! I always heard if the voltage on a lead acid battery was much below the rated voltage that it is probably toast.
Nice work :) i bet that taillight bulb is an 1157. Most auto parts stores still carry the 1154 6v version which I suspect that bike calls for.
Thank you for the info!
Battery technology has come a long way in the past 45 years. The 'Bay has 6v rechargeable AGM batteries for $10 that will fit in the stock battery box. All bulbs need to be working and not blown, replace with stock 6v incandescent not LED. You may need a new diode if it's overcharging like that, the Honda NC50 Express uses the same style 6v for $6 new. Clean up all ground wires at their connection to the frame. If the horn has seen high voltage it could need replacement. Hope this helps!
Thank you for the suggestions!
Love this couple.
"Whoa, 18 volts!!!" *Voltage meter climes to 28v. "Seems like a good way to melt the wires!" Yeah
I have a 1980 KM100 which is what my wife rides for now.
Start with your meter set on AC and test the stator output then move to the rectifier on up.
Jennies Garage and This Old Tony new vids in the same day?!?! Someone pinch me, I must be dreaming!
Cool!!👍👍
A battery will bring voltage up first, then current.
The electrical system seems the same as the old Honda CT90. A simple (downright crude) one diode rectifier and uses the battery as a voltage regulator. The wild voltage output is controlled by the poor old 6V battery, which like the Honda ones will eventually boil dry from stress!
No shame on using the wire nuts. I’ve done the same thing to wire in a new stereo after the previous owner cut the factory plug. They were useful for figuring out what’s what and then doing it right afterwards.
Nice detective work on the wiring. I have an honest question and I'm not sure of the answer. Seeing as the charging system was putting too much power into the battery could the regulator rectifier be faulty and need replacing? It could explain why the battery seems to be cooked. Also did the horn work after your fixing? I didn't see you test it.
I really enjoy your videos! But how could you leave us hanging like this...!?!?! LoL
I hope to make another video about it soon!
OMG!! Where have you guys been ? Is this Christmas in July??? I had one of those a friend gave me. I was going to restore it but I ended giving it to another friend who buys and sells and re-pairs motorcycles.
woohooo! new vidjoe!!
Eyyy, we're on the way to being a daily upload channel!
I guess the battery charging is only one diode and no regulation? There are two coils, one is for the AC headlight the other is for charging the battery. The rest is running on rectified DC from the battery I guess. It's best to get a new 6V battery to start out with.
Your voltage regulator isn't working/hooked up right.
Camera girl busting ou MOM jokes lol love it
Wavin the hand from Las Vegas
Hi!
👍👍
Yeah
That was my first bike
Cameras girls laugh . Love it 😂
by some quirk of the universe, me and Jake are wearing the same shirt! whats the odds of that happening?
I have a feeling I’ll be doing this once I get the head off and fixed on my CB450
What do you want? Funny business or messy electrical system? Yes!
those little rotary valve 100s could be made to scream...one of my little brothers had one
time 16:37.
Both of option1 and 2 has fuse between B (ignition sw) and battery and R in (ignition sw)
B mainly is battery connection to main electrics
R is requlator
Usually generator only supplies power to battery, when battery has been used (like start, which this bike don't have) and most of time power to lights and such are powered via generator, not battery when bike is running. If you have short circuit in your main electrics, fuse needs to be between it and power source.
Your connection don't have it. You can supplie as much as needed to your short from generator and no fuse will save you.
So both option 1 and 2 are better than your connection.
I agree with some of what you say. In my way a blown fuse protects the battery from a short, but not the charging system. In both of the alternate ways, a blown fuse protects the battery and the charging system, which sounds better. However I don't know enough about electronics to know if a short would damage the rectifier. Thank you very much for the comment.
That's like 4x the voltage at idle than if should be. Supposed to be like 6.5 volts max at 3k rpm on a 6v system
2:12 but thats the good smoke! :D
👍👍👍👍👍
👍
👍👍🇺🇸
It's always fun having to deal with past bodgery made by someone who didn't check things before they messed around with it, I'm sure they could have gotten a manual for it at the time, but no, that's the smart thing to do, and people aren't smart... :P
What is your opinion about longetivity of two stroke bikes compared to fourstroke bikes?
Many years ago 4 strokes were known as more reliable. However with the proliferation of high performance four stroke machines it isn't a clear choice. I think in general, regardless of 2 stroke/4stroke, the higher performance the engine, the lower the longevity. Maintenance also is as big of factor as anything. Thank you for the coment!
I'm saying new voltage regulator and new battery, you'll be good....
Awwwww Yyyeeaahhhh!
the age of the bike makes it not required to have the head light on, so you had a choice headlight on or not your choice
Scrambler project??
I think you should just switch the taillight and brake light wires. I could be wrong but i don't think both are on at the same time while braking?
I hadn't thought of that but think they both stay on during braking, and my problem is that the battery is dead. But we'll know for sure once I get a good battery installed. Thanks for the comment!
I think you may need a new reg/rec
Key has two positions: on and ... onner
just checked 1978 was the last year the motorcycle did not have to have the headlight on then 1979 up did
Your son wasn’t he just writing a PW 50 not too long ago
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🥰😍🤩🙂😄❤
If your son sprays candy over the fuel tank & white mud guards, the previous work would be kept but customised to be his own.
wasn't me lol.
Your voltage going to the battery is too high, voltage reg is bad.
Nice socks.
thank you
Kdx 200?????
18V on battery first pull the red caps and fill the cells with water, because the battery is probably very dry. If not helping then battery is toast.