CaptCardboard's Quandaries and Questionable Repairs

Charging systems are a scary nebulous thing for me. No matter what I read about em they never really make any sense to me, so I appreciate all the help from you folks!
 
Yes, you're not charging. Ideally you want low to mid 14's when revved. Yes, start with the brushes, they're a wear item and once they wear too short, charging can stop. New, they're about 14mm long, and the wear limit is about half that (7mm). If they're originals, they should have a wear indicator line etched in one side ......


BrushWearLine.jpg
 
Anywhere near the brush wear limit line is too short IMHO.
75 would a have a mechanical voltage regulator (It's adjustable)
But first things first brushes, good clean connections.
Ohm out the rotor and stator leads.
then check the rectifier. Once all that is known good you can set the regulator.
Cheating is not allowed, don't try to cover up a problem by adjusting the regulator. :doh:
This is it, the whole charging system;
early charging diagram.jpg
 
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I was afraid of that. I don't live this life every day, but I seem to remember charging system while revved should be closer to 14-15 volts.
I suppose it's time to dive into servicing my charging system, or maybe go for a PMA kit that all the chopper bros seem to love. Not having a battery does sound kinda fun.
IMHO that wouldn't be a great idea. Stock system is good when maintained correctly. Good idea to fit modern rectifier and regulator along with new carbon brushes.

From what I can see, on an XS650, a PMA kit is the answer to a question that barely exists.
 
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