Wilsons Sandbox

Well done sir! -- Ian Francisco http://www.scarletfuries.com http://www.facebook.com/pages/The-Scarlet-Furies/121218125931 Re: Voltage Regulator http://groups.yahoo.com/group/DSN_KLR650/message/207151;_ylc=X3oDMTJyNXQ1Z2I1BF9TAzk3MzU5NzE1BGdycElkAzQ4ODM4NQRncnBzcElkAzE3MDUxMjYyNjIEbXNnSWQDMjA3MTUxBHNlYwNkbXNnBHNsawN2bXNnBHN0aW1lAzEzNDg4Mjg5NDM-> Thu Sep 27, 2012 5:50 pm (PDT) . Posted by: "tlz4u@..." tlz4u Hi to all, If your KLR is consistantly over charging your battery, I have come up with a modification that has reduced this tendancy, and applied it to both of my motorcycles. First, much of the overcharging of the battery is due to the fact that the battery sense circuit (brown and white wire) extends from the battery source to the ignition switch, and back to the voltage regulater. This circuit is made of tiny gauge wire, and has several contact points in it (the ignition switch is one), and is quite long. This results in a voltage drop as seen by the regulator. My bike tested out at slightly over 1/2 volt drop. This causes the regulater to sense that the battery is 1/2 volt lower than it actually is, and it happily charges away as it was designed too, trying to make up the difference. My solution is to install a relay. The original sense line is used to activate the coil on the relay, turning it on when the ignition is "on". A seperate, (large gauge wire) is run from the battery positive terminal to the common terminal of the relay. The normally open terminal of the relay is now connected to the original "sense" (brown and white wire) line going into the regulater. This allows the regulater to sense the real battery voltage, without the previously mentioned voltage drop. The relay acts as a switch, preventing the regulater from draining the battery when the bike is not in use. I made this modification (several years ago) to my '83 'wing which see's many miles at higher speeds, and it has dramatically decreased the water loss on trips,and has increased the life of it's battery! I just recently made this modification to my '02 KLR, and expect the same results. Bob Brewer 2002 KLR 1983 GL1100 etc., etc. [Non-text portions of this message have been removed]