G22 Overcharging

[bigstik40]

Originally Posted by Pumper

I am quite sure I have isolated it to the key switch.

The throttle switch had 0.3 ohms resistance and never changed when pushing the pedal several times. Also the wire connector for the switch is of the sealed type and one of the better ones I have seen.

The key switch resistance varied every time I turned the key on-off-on. The resistance varied from 4 ohms to 26 ohms.

I will get a new switch tomorrow and replace the old one.

Wow, that's pretty high resistance, considering that normally it should be pretty close to 0. Glad you got it sorted out. Good information for future troubleshooting. Ray

[Pumper]

I replaced the key switch and still have some resistance left that makes the voltage on the red/white wire 1 volt lower than the battery volts which results in the charging volts to be 1 volt high. I am still trying to find that resistance.

Another interesting fact is I purchased a non Yamaha voltage regulator that looks just like the Yamaha VR, part number on the box is DYTJQ001. When I compared it to the Yamaha I found that the terminal the green wire connects to is connected to the case. That would ground the green wire from the field coil when it is mounted to the frame(frame is grounded) this would cause the charging voltage to never shut off. None of the Yamaha VR terminals are connected to the case.

Any thoughts on this?

[bigstik40]

As I mentioned in an earlier post, grounding the green wire will give your generator full field and give maximum unregulated output all the time. You may be pulling enough current through the field to drop that 1 volt in the wires. You may have found your problem. Ray

[cgtech]

That regulator ought to work fine on a G9, where its mounted on a plastic inner fender. Thats probably where them chineers built it.

[Pumper]

I am not using the "cheap" Chinese" regulator I am using the Yamaha VR. I bought the Chinese regulator to have on hand but I guess you get what you pay for.

I have not yet found the resistance that produces that voltage drop, not enough time in a day. Hope to get to it this week.

Thanks for your input, it helps.

[bigstik40]

Oops , misread your post. I now see that you only "purchased" the bargain regulator but did not install it. I've seen those bargain regulators before with unbelievable low prices and wondered what circuitry they contained. Would also be interesting to see whats in the OEM regulator (besides gold) that makes it so pricey. Good luck on your search - RAY

[Pumper]

The G22 generator that was over charging decided to go to slightly under charging about 14 volts. So I decided to see if the generator is the problem so I disconnected the DF wires(red/wht and grn wires) by unplugging the connector. Now I connected the green wire to the battery neg terminal ran the engine up in RPM and held the red/wht wire to the battery plus terminal no more than 10 seconds, energizing the field coil, and all I got for charging volts was again about 14 volts.

This says the generator is bad I thought I should have gotten close to 20 volts.
I had made a wire harness to plug into the DF connector so I could reach the battery so I thought I better check its continuity. I got 6 ohms through the field coil, that looks OK a little over spec.

Any thoughts.

[bigstik40]

This is really a beauty !!! Just grabbing at straws here, but you could make sure high current cables to the battery are clean and tight. Also check the output voltage right at the generator to make sure there are no voltage drops in heavy cable when putting out current. Another thought, maybe the battery is cooked by now or maybe a poor internal mechanical connection in the battery. Can't think of anything else right now. Staying tuned - RAY

[Pumper]

Those are good suggestions, I will try.

Batteries can do weird things, I had a battery on a 2007 Yamaha that was generating high volts(17-1 the battery was 4 years old so I replaced it and the voltage is now right in spec.

[kidmg217]

Did you ever figure out the issue? I have the same thing happening to mine and cant figure out why the voltage is lower to my regulator.