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Last Updated: August 01, 2011

Voltage regulator, A summary

Before attempting to use all circuits here regarding voltage regulator for motorcycles, let us first differentiate the two system. Not all machine are the same especially with the design of the voltage regulator. There are single phase system that uses half and full wave charging system, and three phase system that uses half wave system..By looking at this block diagrams, you will be able to determine what system your bike uses by following the connection. FJPGVS6ZRZW7


First and foremost, the single phase, the picture above illustrates a single system half wave regulation, you can see that the one end of the stator is connected to ground, via earth ground, the coil has also a center tap on the winding for your headlight and the output will also be regulated by the voltage regulator..this kind of regulator is a single phase half wave system, if the end of the winding is no where connected to ground then the system will be a full wave.






Next the 3 phase system.
This system can easily be distinguished by the three yellow wire, sometimes three white depends on the brand of the bike. when you see one, then its a three phase already. Note that there is no wire for the lighting coil coming out from the stator, this means that the headlight is directly connected to your battery, and this  means also that the onboard battery is larger than those of a single phase system. What good about this system is it can be used on single phase full wave stator by just omitting the other two yellow wires.

By determining your system, you can increase the power available for your additional accessories that is needing huge amount of current such as high intensity discharge for your headlight by upgrading such system, increasing battery alone will not help.

Aftermarket China voltage regulator on the other hand uses different wiring configuration..
but still they are utilizes for a three phase  charging system., again they can be used on single phases with stator not grounded at the other end...

23 comments:

Anonymous said...

THANKS a LOT sir...
planning to convert my mc(Shogun Pro-tulisan) to full wave charging system - DIY,pero di ko pa masyado kabisado,need complete wiring diagram po sana..

More power...
--jeybratt--

LEI said...

shogun pro tulisan (shogun PRO new model) has actually a three phase system..the Fuel injected model of this bike introduced in indonesia uses this system, bolt on. (kung dumating nga lang dito yun..panigurado lahat ng gusto mag dual hid sa shogun will be worry free.

to do this modification, pay attention that you'll be bypassing something on your stator, that is re-tapping of wires will be done, and you need to open up that left side crankcase.

Anonymous said...

aw...mahirap po pala...pass po muna ako sa HID..
sa mga LED nlang po muna..
okey lang po ba ung mga nabibili na LED,ung nabibili po sa DIY shop??ung 12v po..
then panu po mag connect ng tachometer sir>>type R po ung nabili ko..

--jeybratt--

Anonymous said...

THANKS a LOT sir...
planning to convert my mc(Shogun Pro-tulisan) to full wave charging system - DIY,pero di ko pa masyado kabisado,need complete wiring diagram po sana..

More power...
--jeybratt--

Anonymous said...

sir, question po, meron po akong nabili na regulator, 5 wire sya. black,green,red,yellow,pink respectively.

ganito po ginawa ko, hindi ako sure kung tama, pero galing sa stator, white at yellow may AC voltage akong nadedetect. nagsearch ako sa mga forums at eto sabi nila.

green -> green
red->red
yellow ->yellow
pink->white
black->connected daw sa key..

ginawa ko hindi ko na kinonect yung black..

anu po ba ang tamang wiring?..

sinski 2005 model yung scoot ko

more power po.

LEI said...

yung block diagram sa itaas ang sundin mo...yan ang wiring system ng china 6 wire voltage regulator na pang GY6...just omit the other yellow wire...

yung yellow at pink ay sa auto bystarter or commonly called the automatic choke ng scooter..it can be left unconnected if you dont have a bystarter,

sinski ang scoot mo, definitely BIGBOY to, am i right and it uses the 4 pin OEM voltage regulator,

sa wiring did it work?

vanjopogi said...

Good day sir, im planning to use your diy fast charging system on mu vega force as im planning to install 2hid on it.. Only thing is im not sure if what kind of system is there on my vega force.. I'll be glad sir if you can email me your inputs and ways for me to succesfully do this project of mine.. I already got 2 batteries installed on my mc. My email is rkvanjo@registerednurses.com

More power to you sir and keep on writing/blogging things like these.. It helps us DIY enthusiasts learn more... Ive been doing really good doing DIY modifications on my mc lately and this is my latest project.. After i succesfully do this FCS, im planning to install the digital tachometer.. Of course with your guidance again..

LEI said...

@vanjopogi,
vega force of yamaha is a single phase alternator system, in order for you to stable that 2 hid system of yours, first, you need to make your system a full wave by altering the stator and removing the center tap, somewhere in this blog i had posted on how to do this on a block diagram basis. you have to parallel those windings then change your voltage regulator.

vanjopogi said...

By cutting off the yellow wire sir, will alter my stator?

This is what i did according to what i understood on your blog.. Cut off the yellow wire, changed the stacc rectifier to a much better one(mio thailand replacement rectifier, my mates used this on them without cutting any wires). Put an on/off switch just in case it wont work so i can just easily put it back on.

Anything lacking with what i did? Please enlighten me.. Sorry for the so much delayed reply.. I took the chances of reading and gathering more information before i actually did the work.
I am hoping i am doing the right thing.. Fast feedback from your end will lessen my chances of error.. LOL!

Thanks a lot sir..

vanjopogi said...

And one thing.. Even if i put off the connection of the yellow wire, my parklights and tail lights are still something like blinking just like still having been connected to a stator.. :(

vanjopogi said...

Na discharge instead ang baterya ko sir.. What happened? Ano mali ginawa ko? Tnx

janjan said...

May safety switch ako.. Kung Naka neutral ang motor aandar pagmagchange gear ka the motor automatic off.. Every change gear interested txt me 09184446342

goldwin saycon said...

Sir pwede bato sa Kawasaki Fury 125?

Unknown said...

Master tanung q lng po, ayaw kc tumuloy yung kuryente ng vega force q, umaandar sya pero nag pupugak pugak po pag nag silinyador k at yung mga ilaw nya is mahina n..bago din po battery q at sparkplug

Unknown said...

Master tanung q lng po, ayaw kc tumuloy yung kuryente ng vega force q, umaandar sya pero nag pupugak pugak po pag nag silinyador k at yung mga ilaw nya is mahina n..bago din po battery q at sparkplug

Cath Reyes said...

Master tanung q lng po, ayaw kc tumuloy yung kuryente ng vega force q, umaandar sya pero nag pupugak pugak po pag nag silinyador k at yung mga ilaw nya is mahina n..bago din po battery q at sparkplug

Cath Reyes said...

Master tanung q lng po, ayaw kc tumuloy yung kuryente ng vega force q, umaandar sya pero nag pupugak pugak po pag nag silinyador k at yung mga ilaw nya is mahina n..bago din po battery q at sparkplug

Nathaniel Berdan said...

Cath Reyes, If you suspect an electrical issue..here is what you have to do. Turn off all headlights to do this, locate the voltage regulator, and remove the connector, then start the engine by kick start, try revving the engine to see if you can throttle up normally.

If you suspect ignition, then check ignition wire for any damage causing High voltage leak to engine chassis, remove the spark plug for fouling, adjust the gap as necessary.

When an engine is starting but starving for gas, then it is a carburetor problem and probably cause by clogging.

Zhi Hao Looi said...

i'm just able to get 10.2 volt ac from the headlight switch, and it will drop lower to 9.6 if rev higher, is this means my rectifier is dying? And this is my third rectifier, the first one broken, the second one melted, is this because i modified to turn off the headlamps in the day time? (fully on by default)

Nathaniel Berdan said...

Zhi Hao Looi try this to see if your stator or generator is actually in good condition, Turn off all headlights as well as your TAIL light bulb..Disconnect the regulator connector and leave it hanging (no connection to your regulator)..

PS: I do not know your motorcycle model by the way and so the color of the wire for me is unknown

connect the negative probe of your AC voltmeter to ground, anywhere in the metal chassis, set it to 250 volts AC or any settings that is more than 60 volts. turn on the engine and connect the positive probe to one of the pins of the regulator..we are trying to see if the lighting coil generate enough AC voltage without the regulator..it must be close to 20 volts or higher when the engine is rev, for the charging coil, voltage must be near 60volts all the way up to 120volts AC..

if all voltage test is near it..then again maybe your regulator is again failed.

but it does not fail when you put a headlight switch on automatic headlight on motorcycle. If you can tell me how you fitted that on/off switch on your AHO system.

goldwin saycon said...

sir Nathaniel kung naka full wave po ang motor possible po bang ma over charge ang battery?

Unknown said...

Similar to a comment I left elsewhere, have you seen the 3-phase regulators like this with 7 wires? 3 yellow to the stator, red is 12v+, green is ground, black I believe to be keyed 12v sense like the 5 wire single phase units, and a white wire that I have seen labeled as both choke/enricher output, and also headlights.

Do you have any idea what type of output and/or capacity this white wire has? 12vdc? Some lower dc voltage? I assume that it only outputs while the system is charging/engine is running. It also seems like it must be DC With no AC neutral reference (choke is grounded to the chassis/battery).

Some of the references to it being able to run headlights make me think that it may be a normal regulated 12vdc output that is switched. I have seen references to it being an AC voltage, as well as lower dc voltages such as 6 or 10 volts. I am somewhat skeptical that it can run a headlight directly though, and will likely use it to trigger a relay.

I have one on the way to test with, but was wondering if anyone had any further/definite info.

ziggridacosta said...

GOOD DAY SIR.. ANG MOT2 KO MOTORSTAR SCOOTER GY6. SIX MONTHS AGO NACONVERT UNG CDI KO FROM 6PINS TO 4 PINS. MAY HANGING N ISANG WIRE THEN NGPALIT AKO BAGONG BATT KASI NGA MAHINA THEN NAGPALIT AKO NG BAGO, NADISCHARGE UNG BATT AFTER A MONTH.

MAY KINALAMAN BA UNG HANGING WIRE S PAGKADISCHARGE NG BATTERY KO??
O MERON PANG IBANG SIRA N COMPONENT?