Stator Electrical Help 150cc GY6

[jdotfite]

Hey guys, I am finishing up a GY6 150cc engine swap onto my Honda Ruckus. I have everything interfaced correctly, but I am running into a problem with powering my stock Honda Ruckus headlights. The stock Ruckus headlights use two h4 bulbs that run all the time. They are both 35 watt bulbs.

If I hook the headlights up directly to the battery, the battery dies after about 45 minutes of riding.

Next, I broke out my volt meter and hooked it up to my yellow wire and ground, I was getting a reading of around ~40V, indicating my rectifier was not doing its job correctly.

I swapped out the 4-wire rectifier for a 5-wire I had. Tested the line again, this time I got ~10-14V. I tapped my yellow wire and wired my headlights up to it. I wasn't sure if the stock 6-pole could produce enough power for both headlights so I only hooked up one. Rev'd the bike, blew the bulb.

Here is my question. I am reading that I should not be powering these bulbs off the battery and that the battery is only meant for starting the scooter and low drain accessories. Is this true and if that is the case, what can I use to cap that voltage and keep it from going over 12v? Also will using a regulator like this create too much heat? Also, should I be looking to upgrade the stator to an 8 or 11 pole? Would the 6 create enough power to charge the battery and power the two 35watt bulbs?

or

Should I just be looking at upgrading my stator to a 8-11 pole and running the headlights off the battery again. Would the 8 or 11 pole stator create enough power to keep the battery charged while running the lights off the battery? The first idea seems like it would be a lot easier on that battery.

If I go with the 1st idea, I was thinking I could use a relay hooked up to the yellow wire so the headlights are only on when they bike is running.


I would really appreciate any input on this subject. If using a regulator is the way to go, could someone provide a link to one so I know what to order? I really wish to finish this project!! I have been stuck on these headlights for two weeks now.

Here are some progress pics:

Day 1 (last may)

End of Last Season:

Donor Baja 150cc GY6 Scooter:





As of Last Week:

[abscooters]

You should tap the yellow AC wire for the headlights & use a 4 pin reg. There are 2 different 4 pin regs for the 150cc scoot. one for a 6 coil and one for a 8 coil stator. And if everything is wired properly, a 6 should power both bulbs just fine.

For the 6 coil stator you want the 4 pin reg that usually says "FLP" on it somewhere. It is also imperative that the white wire is wired in correctly too, or you will not be rectifying it properly.

looking at the plug it should be wired like this

Red White
Yellow Green

[jdotfite]

May 22, 2009 6:00:10 GMT -5 abscooters said:

You should tap the yellow AC wire for the headlights & use a 4 pin reg. There are 2 different 4 pin regs for the 150cc scoot. one for a 6 coil and one for a 8 coil stator. And if everything is wired properly, a 6 should power both bulbs just fine.

For the 6 coil stator you want the 4 pin reg that usually says "FLP" on it somewhere. It is also imperative that the white wire is wired in correctly too, or you will not be rectifying it properly.

looking at the plug it should be wired like this

Red White
Yellow Green

I have a few questions about your response.

The 4-Pin I have is putting out ~38-40v, that means its not working correctly, right? My 5-pin is putting out ~10-14v, thats what my 4-pin should be around, right?

I can order another 4-pin if it is bad. I was unable to find information about the differences between a 5-pin and a 4-pin. What is the 5th black wire for on the 5 pin? The 5-Pin came stock on the baja, but I can't remember what the black wire was connected to. Also, all the GY6 wiring diagrams I could find only show a 4-pin.

I will also take another look at the plug today and make sure the wires are in the correct order.

I have my white wire running directly to the rectifier right now. My battery does seem to charge fine without the headlights hooked up.

I am glad to hear I may not need to upgrade my stator, but how do I keep the voltage from spiking (anything above 12v) and burning out my headlight bulbs?

I am also going to double check my grounds and keep trying to narrow things down. Is it common for the 4-pin to put out above 12v when reving? I am going to hook up my volt meter and take it for a spin and see what voltages I am getting. How tolerant would you expect my H4 bulbs to be?

[jdotfite]

May 22, 2009 7:49:11 GMT -5 funderp47 said:

This thread: scootdawg.proboards.com/index.cgi?board=talk&action=display&thread=19916&page=2 talks about a Honda Metropolitan's ECU providing grounds. I don't know if the Ruckus is the same.

I like abscooters reply.

Thanks for the response, the Ruckus does use an ECM, but I removed all the ruckus wiring when I swapped the GY6 engine over. Thank you for the link, I know undertheradar from the totalruckus forum, ill have to PM him.

[abscooters]

It sounds as if your 4 pin reg is shot.

As for the 5 pin, there are several different breeds of these too. Some are meant to be used in conjunction with a diode, and there are versions for both a 6 coil & 8 coil. Which is which, I'm not sure how to identify them yet.

I have a new factory in china I'm dealing with that knows the differences in all these regs. However, I haven't ordered any samples yet and done any testing. Communication is very slow. With my busy season here, it will probably be fall-winter till I get around to it.

If I were you I would just get a new 4 pin that works and take it from there, before something else fries.

[stradarx150te]

That thing looks SWEET!! Nice work