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Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: alexd] #89585 11/14/11 12:04 AM
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sandalscout Offline
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Originally Posted By: alexd
From what I see, the "device" attached to the Br/R-W wires is a surge-suppressor...shown in the circuit diagram as two diodes connected in opposite directions.


Interesting. That actually goes along well with the manual. The manual lists all three parts as diodes, but the testing procedure for the diodes is only listed as applicable to "Diode 2" and "Diode 3". I thought that was weird, but assumed it to be an oversight by the writer.

Since it does not seem to truly be a diode, that would explain why they don't list it.


Matt
2009 XT250
2001 KLR650
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: sandalscout] #89590 11/14/11 05:22 AM
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alexd Offline
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It is a semiconductor, but probably better described as a thyristor device. I believe it functions as a high-resistance or open-circuit, until a pulse exceeding a certain design limit hits it. Then, it "flashes over" momentarily to low resistance to smother or damp out the excess power, giving it an alternate path to flow.

Typically surge-suppressors are placed across switch contacts, where the load being switched is inductive (has magnetic properties), and capable of "generating" spikes of voltage. A simple capacitor (in the older days called a condenser) can function similarly, up to a point.

Alexd


(one) 2006 XT225, (two) 2005 XT225, 2006 FZ1
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: alexd] #89591 11/14/11 08:02 AM
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Thanks for posting the diagrams
D1 is a breakdown device across the starter solenoid to prevent back EMF. You will not be able to test it with a meter, beyond the infinite readings you are getting in both directions, which is what I would expect. It wont be causing your regulator to overheat.
I'll download the manual from sandalscouts link so I can work out the function of D2 and D3, but a quick look suggests they are just part of the circuit logic, and nothing to do with power regulation

Last edited by Tigersaw; 11/14/11 08:06 AM.

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Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: Tigersaw] #89601 11/14/11 11:12 AM
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alexd Offline
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D2 relates to the clutch switch. D3 relates to the neutral switch circuit. They are typical diodes; their functions are UNRELATED to the charging circuit/regulating circuit.

D2 is protective; it could probably be removed, but the designers thought otherwise. D3 MUST conduct for proper starting mode function (clutch is OUT, gearbox IS IN NEUTRAL), but could be replaced by a straight through wire, though the designers felt it offered reverse voltage-protection.

I'm not arguing with the designers...they would admit that several variations on the circuitry would also work.

Alexd

Last edited by alexd; 11/14/11 11:14 AM.

(one) 2006 XT225, (two) 2005 XT225, 2006 FZ1
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: alexd] #98440 06/27/12 01:38 PM
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Nabil Alshahoomi Offline OP
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I really appreciate all the help.

The third technician confirms that all the wiring and connections are intact and he said that he replaced the regulator with another used Honda type one and the overheating was gone but he wants to have a look at the XT250 regulator schematic because he is not sure if the Honda regulator will not break down if the bike was driven for a long distance.

Can anybody help me find the the schematic of the XT250 rectifier / regulator:
Regulator Type:Semi conductor-short circuit
Model / Manufacturer: SH629A-12/SHINDENGEN
No load regulator voltage: 14.1–14.9 V
Rectifier Capacity: 10.0 A
Withstand voltage: 200.0 V

I'm still searching the net for this schematic and I need your help to find it.


My First And Last Will Always Be A Serow
SEROWS: 1986 XT225, 1992 XT225, 2002 XT225
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: Nabil Alshahoomi] #99533 07/17/12 08:08 AM
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Nabil Alshahoomi Offline OP
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The Honda regulator failed the long distance driving test on the XT250 as it ended overheating. The technician suggests using a regulator with a higher rectifier capacity. He suggests more than 30A.
What do you think would be the best swap for the XT250 regulator but with more that 30A rectifier capacity.



My First And Last Will Always Be A Serow
SEROWS: 1986 XT225, 1992 XT225, 2002 XT225
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: Nabil Alshahoomi] #99536 07/17/12 08:39 AM
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Chuffa Offline
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I've no idea about electronics, however here is a link to an Aussie supplier/manufacturer of aftermarket rectifier/regulators.

XT Regulator Carmo Electronics

It comes under XT225 bike selection, but the part number it replaces includes the XT250 part # previously quoted in this thread (I think).

They state - "New advanced design - most of our regulator rectifiers now feature highly advanced metal ceramic heat transfer and are built using the latest equipment, making them extremely rugged and reliable."

Just another option.
Regards,
Chuffa


Perth, Western Australia
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: Chuffa] #99544 07/17/12 01:14 PM
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Nabil Alshahoomi Offline OP
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Carmo Electronics doesn't give the regulators' specs so I ended up unable to select the appropriate one with the required Amps.


My First And Last Will Always Be A Serow
SEROWS: 1986 XT225, 1992 XT225, 2002 XT225
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: Nabil Alshahoomi] #99754 07/20/12 12:45 PM
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Nabil Alshahoomi Offline OP
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I believe the best replacement would be the Shindengen FH001 as it has the same specs of the XT250 regulator Shindengen SH629A-12 except the the rectifier capacity which is 35 A.
Here is the specs of the 2 regualators.

XT250 Yamaha:
Regulator Type:Semi conductor-short circuit
Model / Manufacturer: SH629A-12/SHINDENGEN
No load regulator voltage: 14.1–14.9 V
Rectifier Capacity: 10.0 A
Withstand voltage: 200.0 V


The replacement is this one:
FJR1300 Yamaha:
Regulator Type:Semi conductor-short circuit
Model / Manufacturer: FH001/SHINDENGEN
No load regulator voltage: 14.1–14.9 V
Rectifier Capacity: 35.0 A
Withstand voltage: 200.0 V


This replacement will require some wiring modifications. Any ideas or comments are most welcome.

Alshahoomi


My First And Last Will Always Be A Serow
SEROWS: 1986 XT225, 1992 XT225, 2002 XT225
Re: Rectifier/Regulator Overheating XT250 2007 Report [Re: Nabil Alshahoomi] #100785 08/12/12 02:03 AM
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Nabil Alshahoomi Offline OP
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I found similar RR but with a difference in the withstand voltage which is 40 V and more rectifier capacity which 50A. It is a Shindengen FH012AA(1D7-81960-00-00) while I needed FH011 (5JW-81960-00).

I also bought a new genuine battery YTZ7S.

Will this Regulator / Rectifier FH012AA cause any electrical problems in my bike electrical circuit or cause any damage to my bike electrial components?

Last edited by Nabil Alshahoomi; 08/12/12 02:15 AM.

My First And Last Will Always Be A Serow
SEROWS: 1986 XT225, 1992 XT225, 2002 XT225
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