TS125 charge light

[stevebod]

Hi There.
I was out on the TS125 the other day and as the sun went down I deployed the headlights and noticed the charge light was on dimly.
As the journey progressed the light went on and off a few times and then stayed on permanently.
The bike got me home, but the problem remains.
Running a few tests, the light actually stays off at tick-over, but comes on as the bike is rev'd.
I've checked the dynamo brushes which seem to have plenty of wear left on them.
The bike is fitted with some kind of solid state regulator.
I'll try and attach a video of the light and a photo of the regulator.
Are there any tests I can run?

Video can be found here.......
http://www.steves-workshop.co.uk/files/ ... -light.mp4

[Gerryman Ts125]

What is the load reading at the battery with the ignition off, on, running? Following that what are the readings just on the naked Solid state points box?

Ohh and what are the 6v readings at the dynamo. As it all should be 6.5v - 8v. The faster the dynamo turns the more the battery/Regulator/ system should read.

[breakwellmz]

From your photo the earth connection top left looks suspect. As it`s easy and simple to do I would sort that, and clean all other connections as well first.

[Blurredman]

The way the light is acting does make me wonder earthing/connection corroding. But yes we need voltage details too.

[stevebod]

Thanks for the replies and suggestions.

I've just done some measurements.
At the battery, there is........
6.14v with the bike switched off.
6.18v with ignition on.
6.67v with the engine running.
6.678v with it revving.

At the dynamo I can measure 7.85v running.
This increases to 8.3v when the headlight is turned on.

@ GerrymanTs125 - can you explain your comment "what are the readings just on the naked Solid state points box"?
I am an electrical dunce, but the bike has points ignition but a solid state regulator.
I'm am not sure which connection is which at the regulator to be honest.

Thanks.

[dave47]

The vape regulator should give 7.0-7.2 volts above tickkover.
More than 7.4 is gassing voltage IE bad.

[stevebod]

Thanks Dave.
So does the ignition light come on if the voltage is too high?
It makes sense that it might.
I can't understand why the voltage at the dynamo increases when the lights are turned on. I would expect the extra current to draw down the voltage.

[dave47]

I am as puzzled as you. The above excerpt from an MZ manual might help.
The most likely cause, and the first thing to check anyway, is a loose or bad connection somewhere.
It might also be a good idea to recharge the battery if you have a charger. Sorry I can't be of more help.

[stevebod]

Many thanks Dave, that's a useful paragraph in the manual.
The fact the light is not steady, but flickering, also fits with a loose connection somewhere.
Yes - I will charge the battery and in the meantime, trace all the wires I can see to check for a connection issue.
Cheers.

[DAVID THOMPSON]

I HAVE FOUND IN S0METIMES THE CHARGE LAMP NEEDS TO BE TYPE recommend BY THE MAKER OF THE CHARGING SYSTEM
THEY USE IT TO SET THE VOLTAGE AND CURRENT WRONG BULB UP SETSTHINGS

[breakwellmz]

Many thanks Dave, that's a useful paragraph in the manual.
The fact the light is not steady, but flickering, also fits with a loose connection somewhere.
Yes - I will charge the battery and in the meantime, trace all the wires I can see to check for a connection issue.
Cheers.

I seem to remember weak brush springs causing charging light flickering at higher revs.

[Jay Bee]

Is the charge lamp supposed to still function normally when the original electro-mechanical regulator has been replaced with an electronic one ?

[dave47]

Is the charge lamp supposed to still function normally when the original electro-mechanical regulator has been replaced with an electronic one ?

Yes. I have the same regulator on my ts125 and the charge light works normally, although I have disabled the indicator warning function.

[stevebod]

I have been through the wiring and have cleaned up earth points and checked for loose connections.
I found the orange wire at the regulator was sometimes arcing/failing when it was jiggled. So I pressed the crimp tighter to make it secure.
Today I fitted new brushes to the dynamo too.
The light now stays off unless the headlight is one.
Then it glows dimly. Not sure if this is problem - perhaps not.
However, more concerning is a noticeable switch between dim and "not-so-dim" when the headlight is on.
Revving the bike makes the light brighter too.
The video attached shows the light behaviour.
I would value any thoughts.
It is MZ club on Sunday - I may try and get there with the lights off and then use them on the way home to see if the bike is actually draining the battery.

Video link...............
http://www.steves-workshop.co.uk/files/ts125-charge-light2.mp4

[stevebod]

Well the ride to MZ club yesterday was uneventful (in a good way). No electrical trouble or flat battery.
Also - despite seeing the charge light on dimly the night before with the headlights on, it was not visible in the daylight.
I also wonder whether the change in brightness I was seeing was just the regulator switching between dynamo and battery power, but I am not sure how they work to know if this is a possibility.
I will continue to run it and monitor the charge light.