burning headlights problem

[scootdoggydog]

today i installed a new engine its a Forsage and it runs pretty good but at first my headlights were kind of dim i revved it up and they got brighter so i took it for a ride and then i noticed i didn't have any headlights so i switched to the brights and the were dead too but the bright light indicator on the dashboard was really bright for a while in fact it was so bright it was almost blinded me and then it went out by the way my head light bulbs are 12v 18/18w so i checked the fuse and its still good and then i checked the battery and it said 13v then when i started the scoot it still said the same thing 13v i dont know what to do now i have no headlights actually i have a couple laying around they are dual purpose headlights 12v 18/18w with both regular and bright functions but one of them the bright light is burned out and the other the regular light is burnt out i would put them in if i thought they wouldnt burn up too

so what can i do to figure this out so i can fix it

[spacecowboy]

Electrically, it sounds like the generator is putting out a much higher voltage than your lights were used to.

[scootdoggydog]

should i try using 12v 35/35w bulbs

i put in the 12v 18/18w bulbs where only 1 highbeam works on 1 and only the reg works on the other when i first start the scoot they are very dim while idling at about 1500 rpms but with just a little throttle they get brighter than they ever were if i give it too much throttle i know they will burn out im going to try the 35w bulbs when they get here i hope they dont burn out or melt anything

what else could i try?

[anhoa]

Yes...try the 12v 35w/35w. I just got one High beam blew up yesterday after 30xx miles. I always run High beam during daylight. Now I have to live with Low beam until it blows out. It's normal. I have a spare under seat.

Anhoa

[gy6rocket]

sounds like an incompatiable stator > regulator. But it may just be the bulb wattage is different. I would try the 35's also first.

Where did you get the engine? I've never heard of Forsage.

[scootdoggydog]

i got it from t-motorsports it says FORSAGE on the cvt cover




so does the regulator/rectifier regulate ac to the headlights?


.

[gy6rocket]

Depends on how the bike is wired, you will have to trace it to know for sure. DO you know which stator your old engine has? I know my T motorsports engine came with an 11 coil stator which is not common on stock scoots. If so you will need a new regulator as the 11 coil puts out much more juice than the 6 or 8 pole stator. Is there 3 yellow lines coming from the engine harness?

[scootdoggydog]

no i dont know what stator i have but it has a 4 pin connector with 3 wires only 1 yellow and 2 seperate single pin bullet connectors

if i trace my wires what am i looking for to determine if the regulator controls the ac to the headlights

[funderp47]

scootdoggy,

You have asked a question I have brought up here a number of times. Does the regulator regulate the AC to the headlights?

At first, I thought the rectifier/regulator was ONLY for providing battery charging and other small DC loads. I thought the stator and headlights were matched so that the headlight load kept the stator voltage from going too high.

Then I had a headlight burn out. During its replacement, I measured voltage at the headlight with no bulb and with a new bulb. The AC voltage remained about the same and did not go higher than 14 volts AC with or without a bulb. So it SEEMS that the regulator "clamps", or regulates the AC to the headlight. Since I've never seen an internal schematic of our type regulators, I don't really know.

gy6rocket seems to have the right idea. The simple 4 wire regulator is single phase, and only has two stator wires going to it. Possibly, if you feed the regulator from a stator with a higher output voltage and wattage capacity, it might overload the regulator and fry it.

It seems you have to be really careful when changing parts to ensure the stator and voltage regulator are matched to each other. There are numerous other threads about electrical problems that seem to show that.

I also don't know if it's possible for the regulator to be able to charge the battery, but NOT be able to regulate AC to the headlight. Sorta half-fried.

From your description, it seems you have a stator for a 4 wire regulator. On mine, the yellow wire provides AC to the enricher, input to the regulator, and AC feed to the light switch.

Sorry I can't be more helpful.

[scootdoggydog]

thanks for the help

i think theres something wrong with the stator

i put in 12v 35/35w headlights and at idle there is little to no light from them but with more throttle/rpms they get brighter and burn out at 4000 looked like a flash from a camera

my stock lights are 12v 18/18w they put out only very dim light at idle problably like 1 candlelight each and they light up bright and burn up quick at higher rpms around 3k

any help, ideas or suggestions please

i want to get a look at the stator so im going to remove the flywheel im gonna get a 27x1flywheel puller is there anything else ill need like an impact wrench or strap wrench?

i problably try my old stator from my other engine to see if that works while im at it

[motomech]

You can run the puller in with an air wrench(start with low setting), but if you don't have access to one, a ratchet and socket will work.
With the puller in snug, strike the end of the extractor with a hammer and the flywheel will pop off.

[scootdoggydog]

how do i remove the flywheel rotor nut?

do i need some kind of variator tool or impact wrench? i tried a strap wrench to hold it in place but that nut is really on there tight!

[schoei1]

Here you go:

cgi.ebay.com/ebaymotors/_Other-Vehicle-Parts__GO-KART-ATV-SCOOTER-GY6-FLYWHEEL-PULLER-L-K_W0QQitemZ260290057417QQadnZOtherQ20VehicleQ20PartsQQadiZ2878QQcmdZViewItem?hash=item260290057417&_trkparms=72%3A543|39%3A1|65%3A12|240%3A1318&_trksid=p4506.c0.m245

I purchased one about 6 months ago and wow, it was easy!

[scootdoggydog]

isnt that the tool you use to pull the flywheel off of the rotor shaft after you get the rotor nut off?

[wf1761]

That's a flywheel puller, make sure you get one for a 150cc flywheel. To get the nut off you need a impact wrench.

[scootdoggydog]

the stator was the problem when i put in the old stator from the other engine the lights worked fine because the stator was wired for it the new stator is wired for a all dc load see scootdawg.proboards59.com/index.cgi?board=talk&action=display&thread=8929&page=1 trailtech.net/media/electrical/dc_conversions/ktm_dc_conversion.pdf not all stators are wired the same after that i thought the old reg/rec would work but it didnt i fried one and another wouldnt charge the battery so i had to get one especially made for dc i also floated the ground but i didnt know the starter was grounded to the engine and needs a ground to work i hope i didnt mess it up