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Generator Repairs and testing - UK & Europe

  • Rexs Speedshop
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Generator Repairs and testing - UK & Europe was created by Rexs Speedshop

I did this video to show how we rate the output of a generator for a someone wanting to see what testing we did. We're using an XT500 generator which is a split AC/DC generator and is the exact same type used on 99% of vintage enduro bikes of the 1970s.

We often get requests to make generators on these bikes more powerful. However just simply adding a few more turns of copper wire in a random fashion often makes the output worse! We've taken a lot of time trailing different winding configurations and trying different techniques to get more power. You can imagine how long it takes to test a new wind - having to wind it, mount it to the test rig and then run it fully (the full testing often takes nearly an hour). If its wrong or un-stable you have to start again. Fortunately we now a have a few rules we can apply to get us near if not bang on an improved output or 12 volts from a previously 6 volt winding first attempt.


I should point out that this is a 6 volt winding being regulated to 12volts. The fact it won't fully power headlamp until 2,750 RPM is normal for this config. With a lighting coil wound for 12 volts it should start charging and power the headlamp fully from about 1,600 RPM.


Another way some people try and go 12 volt is to cut the earth on the generator winding and feed this along with the top tail to a DC regulator/rectifier unit. We can demonstrate that lifting the earth wire and connecting the winding to a 12v DC regulator reduces the power available so much that the headlamp is not fully bright until 5,000 RPM. Also by attaching a thermocouple to the winding that it runs dangerously hot when feeding a DC only regulator. Normally the XT lighting coil runs at 80-90 degrees C supplying full power in AC/DC mode. In pure DC it runs at nearly 150 degrees C!




www.rexs-speedshop.com
Electronic Ignition Design & Manufacture*12 Volt Conversions*Electrical Parts*Generator Rewinds & Overhaul
The following user(s) Liked this Post: Makotosun, Blackhat250, Bigdog302, FrankC
Last edit: 19 Feb 2016 01:02 by Rexs Speedshop.
19 Feb 2016 00:39 #1

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Replied by Blackhat250 on topic Generator Repairs and testing - UK & Europe

Keep up the good work, amazing statistics ,,, :Throttle
If you aint mixin gas " you aint haulin Ass
19 Feb 2016 07:22 #2

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  • Rexs Speedshop
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Replied by Rexs Speedshop on topic Generator Repairs and testing - UK & Europe

You can sort the wheat from the chaff with this equipment! B)
Electronic Ignition Design & Manufacture*12 Volt Conversions*Electrical Parts*Generator Rewinds & Overhaul
19 Feb 2016 10:02 #3

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