Scooter generator voltage regulator relay circuit. Scooter circuit diagram

The relay-regulator, or voltage stabilizer, plays important role in the work of modern scooters, the main task of which is voltage stabilization. At a moped speed of 60 km per hour, the generator is capable of generating voltage up to 35 volts, and without its stabilization, this can lead to the failure of all moped electronics, including the battery. The article will tell you what a voltage regulator is and how to check it on a scooter.

Relay-voltage regulator for a scooter four-pin

What is a voltage regulator used for?

The relay-regulator stabilizes the voltage of the scooter generator for right level, not allowing him to increase or decrease the rate more or less than the norm. This prevents on-board voltage surges from going beyond the established limits (depending on the boards, this is 12-14 V) and spoiling the work of consumers whose resource is designed for no more than 13 V.

That is, this part takes over the impulses that occur during the operation of the scooter (turning on the headlights, the starter button) and transfers the resulting thermal shock to itself. In this case, all the heat that could be deposited on the contacts is generated in it and removed through the device.

In addition to voltage stabilization, the relay also converts alternating current in constant, which is necessary for charging battery.

Moped manufacturers install charging relays with different parameters on scooters and select them individually for each. Depending on the controller circuit, the connectors also differ. At Chinese models usually 5 terminals (daddy), Japanese ones have 4.

Scheme and principle of operation

The operation of the stabilizer for all models is almost the same and consists in distributing the current supplied from the generator for its stabilization and further distribution to consumers.

The operation of the stabilizer is almost the same for all models.

The main peripheral consumers of the scooter include:

• battery;
• indicators;
• light bulbs;
• sensors;
• concentrator;
• other nodes;
• starting enricher.

How does a stabilizer work? The basic principle of its operation is to perform the function of a transformer, which lowers the voltage to an optimal level acceptable for operation. electrical appliances, and also stabilizes the network and prevents unexpected power surges.

In the event of a malfunction of the relay, the scooter devices fail, wear out quickly or burn out.

To avoid these problems and their undesirable consequences, you should know the basics correct operation electrical circuit and voltage nodes of the scooter (Figure 1).

The pinout diagram of the voltage relay and the taps of the main models of scooters

The pinout of the relay-regulator is standard for all models of scooters Chinese made.

Scooter relay-regulator pinout

The stabilizer has an aluminum case and plastic contacts, each of which has its own wire. Each pin has a different wire color. This makes it convenient to connect the device to the wires if the plastic connector is worn out. It is necessary to connect the wires to the contacts according to the electrical diagram (Figure 3).

Wiring diagram connection of the relay-regulator

Signs that you need to check

If the battery on the scooter often runs low, and it is still quite new, this means that there is a malfunction in the relay-regulator. As practice shows, it burns out quite often. At faulty device The battery stops fully charging and loses its capacity. This means that you won’t be able to start the scooter from the button, you will have to start it with a kickstarter.

Another hallmark Incorrect operation of the device may be the frequent burnout of incandescent bulbs. By themselves, they are durable and have a good strength resource, but are quite sensitive to voltage drops. This happens because the optimal voltage in the scooter network is considered to be 12-13 V. Increasing this value even by 2 V reduces the life of the electronics and components by 2 times.

The greater the deviation from the norm, the greater the likelihood that something will burn out in the scooter. Therefore, when starting the scooter from the starter during a power surge at faulty relay Bulbs usually burn out.

The symptoms of a regulator malfunction are identical for all models of Chinese scooters. They are especially typical for charging relays for scooters of Chinese models with an engine capacity of 50 cubic meters. Therefore, before making a decision to replace something in electronics, testing of systems and devices should begin with a relay-regulator.

For all models of Chinese scooters, the signs of a regulator malfunction are identical

How to check PP with a multimeter on a moped?

Checking the relay-regulator on a Chinese scooter is carried out using a multimeter with a voltmeter function. For this purpose, a simple DT-830 (or equivalent) is usually used. It is better to carry out diagnostics and measurement of the output voltage on the removed device.

Check algorithm:

1. It is necessary to unscrew the fairing with the central phase and find a device with 4 wires on the frame: red, green, yellow and white.
2. Then start the scooter and Idling check the voltage: measure it between the green and red wires, setting the multimeter to the limit value of 20 V.
3. If the multimeter display shows the figure 14.6-14.8 V, this is the norm. For stabilizers Chinese mopeds This is the operating voltage. If, at idle, the multimeter shows a value of 15-16 V, this is high rate voltage. This indicates a malfunction of the relay-regulator.
4. Then you need to check the voltage supplied to the lighting lamps. An alternating voltage is supplied to the central lamp of the low (high) beam, so the multimeter should be switched to the alternating current measurement mode with a parameter of 20 V.
5. Next, we measure the voltage between the green and yellow wires (green is the moped's common electrical network). If the multimeter shows a mains voltage of up to 12 V, then electrical appliances are working without additional load.
6. If at idle this value is 16 V and higher, and with a sharp increase in engine speed it jumps to 25 V - the device does not stabilize the voltage and, therefore, does not work. With such indications, the device must be replaced with a new one.

Using a multimeter, they check the relay-regulator on a Chinese scooter

On 4T scooters, the relay-regulator is checked using a tester. Usually a mechanical tester is used for these purposes, although there are also electronic models.

In order to take a measurement, you need:

• switch the device to the KiloOhm mode and remove the regulator;
• then put the probes on the first pair of leads (AB). The tester should show a value of no more than 18 kOhm;
• after that, we change the position of the probes on the terminals in the opposite direction (VA) and measure the voltage again - the arrow on the device should show 0;
• then we install the probes on the next pair of leads (SD) and measure the readings on this pair;
• interchange the probes (DS) and measure the indicator again;
• the rest of the measurements have no contact and are not checked. The indicator when checking them should be zero.

In this way, regulators are checked on popular Japanese models small engine brands such as Honda (Leard, Dio, Tact), Suzuki, Yamaha.

Replacing a faulty relay-regulator on a scooter is not difficult

How to replace a faulty relay-regulator on a scooter?

If the battery contacts are not supplied charging current with a properly working generator - you need to change the stabilizer. Replacing it yourself is not difficult.

To do this, do the following:

1. Place the scooter on the center stand.
2. Find the location of the device in specific model moped. If you can’t find it right away, you can use the instruction manual.
3. Remove the cladding. Depending on the model of the moped, the stabilizer can be located on the front (under the front plastic), in the back, or under the seat. In this case, the underseat space is removed along with the seat.
4. Unscrew the device with seat with retention of fasteners. As a rule, the relay is attached to the scooter frame with a bolt, less often with a self-tapping screw.
5. Disconnect the connector chip and fix the new regulator fastener. The installed device must have a pinout and connector similar to the replaced one, and be suitable in terms of parameters for this particular scooter model.
6. Connect the relay-regulator on the scooter to the standard connector and assemble the remaining spare parts in the reverse order of disassembly.

How to make a relay-regulator with your own hands?

To make a relay-regulator with your own hands, you need a diagram and a little knowledge. The basis of the model homemade regulator the principle of parsing the generator and outputting a separate end of the wire from the ground is laid.

As a circuit, you can take the connection diagram of the relay-regulator (Figure 3), and on its basis assemble a single-phase generator.

To collect the stabilizer you need:

• disassemble the generator and remove the stator from the engine;
• then you need to unsolder the mass from the generator, solder a separate additional wire to it for winding and bring it out. This wire will be one end of the winding. The second end is the generator wire;
• after removing the wires, you need to assemble the generator in the reverse order.

With such a device, the generator has 2 wires (there should be 3 in total). You can connect the stabilizer as follows:

Do-it-yourself relay-regulator manufacturing scheme

At the end of the process, you need to connect the yellow wire from the old regulator to the “+” terminal in order to get a constant voltage on the boards of the network. Check the received voltage regulator on the scooter. This is the creation process homemade device can be considered complete.

The relay-regulator is a very useful and necessary thing for normal operation moped. However, it requires attention and constant monitoring of its work. Therefore, if the device is out of order or its performance is unsatisfactory, it is better to replace it with a new one, the cost of which today is from 300 to 500 rubles.

The voltage regulator on a scooter is also called a relay regulator - this is the most important detail all electrical system scooter, which in addition to providing basic functions helps the battery last longer and better. But the main task of the regulator relay is to ensure a stable supply of current that comes from the generator. After the current has entered the relay-regulator, the part begins its correct distribution to all necessary appliances, including light bulbs, battery, sensors, indicators and others. According to its purpose, the relay can be compared to a transformer that receives and distributes electricity. Without it, the current will simply go in the wrong amount, which threatens the instant failure of all devices. Depending on the model of the scooter, the relay prevents the generator from producing a voltage greater or less than the norm; in more frequent cases, this norm ranges from 12 to 14.5 volts. All current consumers (headlights, turns, sensors, etc.) are designed to use up to 12 volts.

It is also worth considering that initially the scooter generator produces an average of 30 to 35 volts, but at the start of operation, the 4t scooter voltage relay-regulator allows you to reduce this figure to an acceptable 12-14.5 volts. Another important task of this part is that it receives alternating current from the generator, turning it into direct current. If the voltage relay breaks, you face rapid wear of all electrical appliances, the light bulbs will burn out over time and will have to be changed until they receive D.C. in the maximum allowable amount.

What does a relay controller look like?

This detail is outwardly quite small, it looks like a small aluminum radiator. It works great with a thyristor, which has a flat surface and is located under the heatsink. The task of the thyristor is to normalize the voltage during jumps above or below normal. The relay-regulator is located in the front of the scooter under the front plastic, it is easy to find due to the noticeable appearance. Considering the part of Chinese 4t scooters, the characteristics of the part and its type are selected according to the scooter's instruments, location and characteristics. We strongly recommend that you buy a relay exactly for your scooter model, otherwise the connectors will not fit.

Checking the Regulator Relay on a Scooter

If you notice that the bulbs on your scooter often burn out, even after replacement, this happens after a certain period, most likely your relay regulator has broken. But before replacing, you need to make sure of this by checking the part with a tester. To do this, take a mechanical or electronic tester. First of all, you need to configure the device by turning on the KiloOhm mode. Next, you will have to remove the relay from the scooter and measure the indicators at the conclusions that are marked in the picture below.

First of all, we measure the indicators of the AB terminals with a probe, they should show 18 kOhm. Next, we swap the probe and check the conclusions of the VA, the tester should show 0 kOhm, that is, do not react in any way. If the tester starts to react, most likely the relay is broken. After that, we check the conclusions of the LED, the indicator should be within 33 kOhm. By swapping the conclusions on the DS, the voltage should increase slightly, for example, to 42 kOhm. In other cases of ringing the conclusions, changing them (BP, DV, etc.), the tester should not respond to the action, the mark should show about ohm.

Important: given example relay tests were carried out on Japanese scooter brand Honda, so if you own any of the Tact, Dio or Lead models, feel free to check the serviceability in the above way.

Voltage regulator or as it is also called a relay-regulator. This part of electrical equipment is very important and it is on it that the durability of the battery and other electrical appliances depends. The relay performs the function of a voltage stabilizer at the level that the generator produces, then this voltage goes to all the scooter devices that use it.

If the voltage regulator was faulty or absent on the scooter, then the voltage would jump and all devices would quickly burn out. The regulator keeps the voltage within certain limits, preventing it from rising and falling too much, usually within 12-14.5 volts. For example, incandescent lamps suffer significantly even from a voltage increase of 2 volts.

The generator can also produce 35 volts, and the regulator drops this voltage to 12 volts. To charge the scooter battery, you need direct current, it is the regulator that turns the alternating current into direct current. Therefore, the state of the scooter voltage regulator must be watched very carefully so as not to cause trouble.
One way to understand that the relay-regulator has failed is that the light bulbs burn out quickly. They themselves have enough high resource and durability but at the same time sensitive to voltage drops.
By the way, when starting the scooter from the starter, there is a strong voltage surge that can also harm, but the regulator on the scooter corrects this situation again.

Different manufacturers of scooters put different relay-regulators, since each model needs an individual one. Depending on the voltage regulator circuit, the connectors may also differ.

The voltage regulator relay on a Chinese scooter differs from the Japanese one even in the number of terminals. So, in Chinese there are 5 (dad), and in Japanese there are only 4.

But general principle the operation of the voltage regulator in all is almost the same and performs the role of switching the voltage using a powerful thyristor, turning the voltage on and off from the generator.

Regulator diagram on a Japanese scooter:

How to check scooter voltage regulator?

To check, you need to stock up on a multimeter that has a voltmeter function. It is needed to measure the voltage at the output of the voltage regulator.

To measure the voltage, you first need to get to your destination. To do this, you need to remove the front fairing. As a rule, it is screwed on with several nuts and rivets (for example, on Honda dio 3 nuts and 4 rivets). Remove the fairing carefully, it is easy to damage. There we need to find small box which has 4 exits (some scooters have 5 exits). The outputs have the following colors: green , red , yellow and white .

In order to measure the voltage, the scooter must first stabilize in operation, that is, the idle speed must be stable. You can put it on the bandwagon, start it and wait for stabilization. If, or does not hold idle, then read the article:. If all is well, then you need to measure the voltage between the red and green wires. Our measuring device set to 20V, measurement mode constant voltage. If the voltage is within 14.6 - 14.8 then this normal voltage relay-regulator. If the regulator is faulty, then this value can fluctuate even by 5V or more in any direction. If the value is less than 14.5V, or exceeds 15V, then the regulator is faulty.

Now you need to check the voltage supplied to the lighting. Since an alternating voltage is supplied there, we also set our multimeter to measure an alternating voltage of 20V. To measure the voltage supplied to the lighting, you need to measure it between the green and yellow wires. As a rule, the norm for lighting is the voltage in 12 volt, most incandescent bulbs are designed for just such a voltage. + - 0.5 volts is allowed. Do not forget that the scooter is idling and if you add speed, the voltage will rise, but it is not even permissible for the voltage on the regulator to rise to 13+ volts. If the regulator is faulty, the voltage may rise higher. For example, up to 15-16V, but even 13 volts of voltage is harmful for incandescent bulbs. The regulator is clearly defective. Especially considering that it's idling engine.

If you see that the voltage regulator is not working, then you need to urgently replace it. Otherwise, very soon other devices will be added to it that simply could not withstand the high voltage.

A 4t scooter voltage regulator relay can be bought for 500 rubles.

If you do not understand what and how to check, or have additional questions, you can ask them in the comments or find the answer in the video:

Do-it-yourself voltage regulator for a scooter

You can make a relay-regulator with your own hands, this requires a little knowledge and a scooter voltage regulator circuit. We will make a voltage regulator on chinese scooter with your own hands. Most cheap option, is to take the shunt voltage regulator. The nuance is that for good work you need to disassemble the generator and remove the wire from the ground with a separate wire.

It was decided to make a voltage regulator with your own hands for the reason that Chinese counterparts so lousy that there are simply no words. We look at the photo diagram of the Chinese voltage regulator:

We will assemble a single-phase generator according to this scheme:

In order to make a relay-regulator, you must first disassemble the generator and remove the stator from the engine. Now we see this picture:

The photo shows the mass that needs to be soldered, and we need to solder a separate wire to the winding to it. Then it needs to be brought outside. It is this wire that will be one end of the winding. The other end is a white wire.

Greetings to all! “Flew” with me somehow voltage regulator(Not a relay-regulator, do not confuse) on a Chinese 4 tactic, buying a new one was not planned, since the regular PH on all 4t is shit, I got on the Internet to look for a diagram. I didn’t have to look for a long time, I found a very simple and cheap option: shunting pH. But for proper operation, it was necessary to disassemble the generator and disconnect the wire from the mass, and output it with a separate wire .. Well, okay, I won’t explain further, because not everyone fumbles in electrics. In Chinese 4t, as a rule, there are such launch vehicles: The scheme is shit, the efficiency is shit, the resource is shit. We assemble this one (For a single-phase generator, in our case):
For three phase:
We have two options for connecting a home-made launch vehicle, I won’t pull and I’ll tell you what and how: The first option (with alteration of the generator): 1) We disassemble the generator, remove the stator from the engine and this is what we see:
Important: Where it says “It needs to be soldered off”, solder a separate wire to the winding and bring it out, this will be one end of the winding. The other end will be the white wire Everything done, we collect the generator back. We should get it like this:
That is, we have two wires coming from the generator (In general, there will be three of them, but we will need two). I will not describe the connection of the RN further, I will show a better picture:
Done, it remains to connect the yellow wire from the old launch vehicle to the “+” battery. On this, the first version of the alteration is completed. Now our board. the network has a constant voltage.

This article will focus on troubleshooting the scooter battery charging system. If your scooter battery is constantly draining, then there may be a problem with the battery power system. You will need a multimeter to test this system.

At voltage onboard network scooter 12 volt battery is essential for the normal operation of the moped, as it provides electricity to its starter and carburetor starting enricher.

The scooter's alternator starts producing electricity (alternating current) when the engine is running from 2000-3000 rpm. With the help of a converter-stabilizer, the alternating current is converted into direct current, which is needed to charge the battery. The stabilizer ensures that the battery does not overcharge. If the battery needs charging, the stabilizer passes current to it. When the battery is fully charged, the stabilizer turns off and no current is supplied to the battery.

If there is no current flowing to the battery when the power system is damaged, it will not charge. Until the battery is completely discharged, the scooter motor will run. When the battery is completely discharged, the engine will stall and will no longer start (either with electric or kickstarter).

On the other hand, if the stabilizer does not turn off the current, this will lead to the battery being recharged, it will heat up and “boil”, the acid in the battery will flow out. As a result, the battery will fail and may burst.

Rice. 1 Diagram of the scooter battery charging system

Troubleshooting algorithm

Problem: Scooter battery is not charging.

1. Check the fuse and its contacts (clean if necessary). If the fuse is blown, it must be replaced. With a blown fuse, the engine will not start.

2. Check battery contacts. If necessary, clean with sandpaper and tighten the fasteners.

3. Check all wires and plugs of the battery charging system. First of all, check the ground - the blue or black (usually) wire that connects the negative battery terminal to the scooter frame. Sometimes cleaning the battery terminals is enough to get the scooter working again.

4. Check voltage when charging. If your battery is completely discharged, then recharge it using charger or install a known-good battery in your scooter.

4.1. Connect the multimeter to the battery (positive to positive, negative to negative terminal)

4.2. Look at and remember the readings of the device (the normal value is 13.1 Volts, the smallest allowable is 12.3 Volts)

4.3. Start the scooter engine, turn on the low beam headlights, increase the throttle so that the engine runs at about 3000 rpm and look at the multimeter. They should be greater than the battery voltage with the engine not running (14.5 volts plus minus 0.5 volts)

4.4. Troubleshooting

If the readings of the multimeter with the engine running are greater than when the engine is not running, then this indicates that the stabilizer and generator are in order, the cause of the malfunction was in the battery itself.

If these readings are equal to or less than the initial ones, then both the stabilizer and the scooter generator can be the cause of the malfunction (points 5 and 6).

The scooter's wiring can also be damaged, so check that first.

5. Checking the resistance of the generator coils. To do this, you need to find and disconnect the connector on the cable coming from the generator. The check should be carried out with the scooter engine not warmed up.

5.1. Measure the resistance by connecting a multimeter to the white wire (W in the diagram) and ground.

Rice. 2 Connector wires coming from the scooter generator

1.1. If the readings of the device correspond to the characteristics of the scooter manufacturer (for engines of four-stroke scooters with a volume of 50 cubic centimeters - 0.2 - 1.2 Ohm), then the cause of the malfunction can only be in the stabilizer (of course, if the scooter wiring is not damaged). Repairing it at home will not work, so get a new stabilizer and install it on your scooter.

1.2. If the resistance does not match the characteristics, the reason may lie in the damage to the wires coming from the generator. Replace them. If the alternator coils are faulty, they will have to be replaced. (See Workshop Manual, English, part 2, section 14)

2. Checking the voltage stabilizer. The stabilizer has the dimensions of a matchbox, its body is made of aluminum and has ribs for better cooling. The stabilizer is usually installed behind the front plastic lining of the scooter. Disconnect the connector and unscrew the stabilizer. Check and, if necessary, clean the contacts, “ring” the wiring. Check the stabilizer with a multimeter (the figure shows the stabilizer of a four-stroke scooter and a table of values).

Rice. 3 Voltage stabilizer and table of values ​​(in KΩ)

Install the stabilizer back and measure again (point 4). If the problem persists, replace the stabilizer. Honda scooter stabilizers are suitable for Chinese-made scooters.

Recharging the battery, that is, if current is supplied to it despite the fact that it is fully charged, occurs due to a malfunction of the voltage regulator. Troubleshooting is written above (point 6).

If you are forced to replace the generator, then use the scooter repair manual, which is available for download on our forum (link).

I would like to note that to replace the generator, namely to remove the flywheel from crankshaft a special puller must be used. Otherwise (when using a pry bar, hammer, etc.), you risk damaging both the flywheel itself and the crankshaft of your scooter.

Note. Scooters are constantly being improved, changes are made to their design. Therefore, it is not guaranteed that the technical data given in this article will correspond to the characteristics of your scooter. Otherwise, the troubleshooting algorithm is applicable to any scooter with a mains voltage of 12 volts. It is only necessary to clarify the technical characteristics, which are probably indicated in the manual for your scooter.

Troubleshooting the Scooter Battery Charging System updated: March 27, 2018 by: admin