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Friday Night Ride Video / Electrical Fire

25 Oct 2020 07:22 25 Oct 2020 07:27 by rhineman.
rhineman
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Friday Night Ride Video / Electrical Fire #1
I replaced the headlight the other day on my '78 175E with an h4 setup from the vintage spoke:

www.thevintagespoke.com/shop/XT500/Elect...-trim-ring-7-048.htm

I took advantage of the working headlight on my way home the other night by dipping through some trails:

Friday 10/23/20 Night Ride VideoFriday 10/23/20 Night Ride Video

The next morning I had planned a ride. I warmed the bike up and took it for a 3 minute ride around the block. Parked it and noticed it was smoking a lot from under the gas tank. Quickly removed seat and tank and found two wires (red + white) blocked together w/no fuse and the plastic housing on the connector pieces was almost completely melted and burn to a crisp.

I disconnected each wire from the single block they had been connected to and cleaned everything off. When touching the two wires (red + white) together they spark... even with the bike off and key out of the ignition, and a small noise comes from what sounds like the engine block area?

I needed to go riding and didn't want to a wiring fiasco so I covered up each exposed wire separately with electrical tape and the bike still ran fine with exception of the headlight and none of the blinkers working, the tail light and brake light worked. Autolube system, speedometer still working with these wires disconnected.

I'm sure this area got splashed by puddles the night before something is still not right here. I know these 6v wiring harness setups suck as my blinkers all often blow out and sometimes are barely working anyways. I have to the service manual showing the circuit diagram but not the easiest to understand.

The wiring on the new headlight was all soldered, weather sealed, and taped so I don't believe that's the issue. I have them hooked up to a 30amp fuse now to test it and headlight does not turn on when engine is running and engine revving.

Does anyone have any advice or experience with this wiring setup?

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25 Oct 2020 07:43
MarkT
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Friday Night Ride Video / Electrical Fire #2
What burned up was the rectifier... a diode... basically a one-way electrical valve.

What it does is only allow the "+" through of the AC power the stator produces so it can charge the battery.

By connecting those wires together you sent raw battery power to the stator lighting and battery charge coil. Hopefully you haven't destroyed it. Disconnect the red and white immediately. If you're lucky, the headlight will work again. If not, hopefully a connection other than the coil itself burned up.

You need to get a new rectifier to connect between the red and white.

1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250

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25 Oct 2020 08:27
rhineman
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Friday Night Ride Video / Electrical Fire #3
Damn... good to know... I am just beginning to understand the electrical side of maintaining this bike. Will order OEM from partzilla. Thank you!

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25 Oct 2020 09:13
MarkT
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Friday Night Ride Video / Electrical Fire #4
Not that bad even if coil is fried... several available on ebay new for decent prices!



P.S. Nice find on the headlight! Looks like it should fit all the later bikes.

1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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26 Oct 2020 12:42
rhineman
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Friday Night Ride Video / Electrical Fire #5
Thanks, Mark. I am assuming the coil is fried so I will order one of these as well. Battery seems fried via my trickle charger... I am wondering if there is a good recommendation for 6v replacement? I had a Yuasa on there.

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26 Oct 2020 13:06
MarkT
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Friday Night Ride Video / Electrical Fire #6
Battery may have fried with bad rectifier... DC batteries don't like being connected to AC power.

Yuasa might be the best brand out there for the stock-type battery...

Moto-Batt probably makes an AGM to fit... I can't remember if I have one on any of my 175's.

1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250

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26 Oct 2020 14:41
Pete-RT1
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Friday Night Ride Video / Electrical Fire #7

MarkT wrote: What burned up was the rectifier... a diode... basically a one-way electrical valve.

What it does is only allow the "+" through of the AC power the stator produces so it can charge the battery.

Had it caught fire you would have had flame rectification. DC but your bike is on fire so probably best to stick with the diode type :haha

Yamaha RT-1
Yamaha CT1-B
Yamaha CT1-C
Honda XR250

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