Author Topic: Yager/Dink 200i hot stuff/ regulator connector  (Read 1785 times)

Ruffus

  • Hero Member
  • *****
  • Posts: 1742
    • View Profile
Yager/Dink 200i hot stuff/ regulator connector
« on: November 15, 2021, 02:11:43 PM »
My Yager/Dink 200i, which gets anyway a lot of care, was asking for more.
For a couple of days I suspected my scoot not to deliver what's supposed to, a proper voltage into its battery (new LiFePo4- 9amp).

The generator delivered on all three yellow/now brownish cables at 4000 rpm, about 55VAC, evenly on all of them, measured 1-2, 2-3, 3-1.
 So the stator seems to be healthy.

Only suspect now was my rectifier/ regulator. Upon measuring it showed normal 14+VDC feeding into battery.
Nothing irregular IMO, until I touched this 3pole connector between stator and regulator, burning hot.
Opened it, and saw the cause.
(pls see pics)

-one cable within this plug had due to overheating "friendly fire" with its neighbour, melted through its separation and caused this intermitting failure

-since this plug would be on order, I decided to do the "direct" solution to solve this prob

-some layers of shrink-tube to avoid fireworks do the trick

-DC voltage at battery, without lights, lights on and at dashboard with brakelights

Its a common fault on cycles and cars, as many owners complain. For there are from 50-100VAC running throught this undersized plug, vibrations loosen those little prongs and firework starts.
This cables AND regulator are getting pretty warm without sparking too, so its worth to help to keep it "firefree".
« Last Edit: November 15, 2021, 02:19:09 PM by Ruffus »
Happy and safe scootering, Ruffus

CROSSBOLT

  • Hero Member
  • *****
  • Posts: 7763
  • West Tennessee, USA
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #1 on: November 15, 2021, 09:17:00 PM »
Nice volt meter! Where did you get it and where did you put it?

Nice repair! Nice write-up, too!
« Last Edit: November 15, 2021, 09:18:52 PM by CROSSBOLT »
Karl

Three motorcycles 1960-1977 (restored a 1955 BSA)
Agility 50
Yager 200i
Downtown 300i
Navy tech, Ships Engineer, pilot and aircraft mechanic

Ruffus

  • Hero Member
  • *****
  • Posts: 1742
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #2 on: November 16, 2021, 08:54:37 AM »
@Karl txs, bought several of those voltmeters at Amazon.it, inexpensive but they come with different options to mount.

One, the classic, from beneath with a big plastic nut, the other as you see in this pic, with a "quasi" mounting frame for applications which are not that accessable from behind.

Power I usually take from "switched 12V +" , hooked into ignition switch, black/blue (pls see diagram).
Shows then of course 0.5 to 0.7 V less than real battery value before start or idle.

 Other than that, scoots got 12V charge plugs, cabled direct to the battery.
Put one reg/rec on stock too, don't trust extended driving with sparks from former owner.
« Last Edit: November 16, 2021, 08:57:45 AM by Ruffus »
Happy and safe scootering, Ruffus

Iahawk

  • Hero Member
  • *****
  • Posts: 2637
  • Eastern Iowa, USA
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #3 on: November 16, 2021, 01:16:50 PM »
Ruffus, your problem solving skills are second to none! What an eye opener to see the melted connections. Thanks for the detailed explanation and pictures.
2010 People S200 - sold after 8 wonderful years!
2014 Ninja 300
1996 Honda Helix
1984 Honda Nighthawk 650

Ruffus

  • Hero Member
  • *****
  • Posts: 1742
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #4 on: November 20, 2021, 05:39:58 PM »
As I already mentioned, if there is something to improve, it has to be done.

Thinking hard by watching my YAGERs poor generator/regulator connection, I found automotive grade connectors "Superseal", the kind which is used on your cars motor compartement. Must be  sufficient for my Yager too.

There where anyway burnt/corroded parts at the ends of its yellow charger cables, (pls see pics) so off they go. This corroded end parts of my cables were partially responsable for heating up the connector, its resistance worked like in heated handlebars, only uncontrolled.

Those Superseal crimp-style connectors
 (pls see pics) are doted 12-48VDC and 20 A.

A little bit tricky to crimp in situ, but all in all a proper replacement. Its kind of puzzle to find the right slot to put. Once in place (prongs) it's nearly impossible to unlock again. So do a dry-run before.
After completing, testrun, all systems working and plenty of voltage.

Another possibility would be (pls see pic) this six- slot lever connector. It's not sealed, which could be done, and rated for 400 VAC/ 32 A. Easier, cheaper and might serve the same, but does not look as good than the black one.
« Last Edit: November 20, 2021, 09:23:40 PM by Ruffus »
Happy and safe scootering, Ruffus

Ruffus

  • Hero Member
  • *****
  • Posts: 1742
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #5 on: November 20, 2021, 05:45:14 PM »
..some more pics to this subject.
Finalisation and lever style connector..
Happy and safe scootering, Ruffus

CROSSBOLT

  • Hero Member
  • *****
  • Posts: 7763
  • West Tennessee, USA
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #6 on: November 20, 2021, 06:54:08 PM »
..some more pics to this subject.
Finalisation and lever style connector..
Look good! Add silicone dielectric grease if you haven't already.
Karl

Three motorcycles 1960-1977 (restored a 1955 BSA)
Agility 50
Yager 200i
Downtown 300i
Navy tech, Ships Engineer, pilot and aircraft mechanic

lbmcconnell

  • Newbie
  • *
  • Posts: 18
    • View Profile
Re: Yager/Dink 200i hot stuff/ regulator connector
« Reply #7 on: May 19, 2022, 02:01:28 PM »
This look so sexxy!!!

An Error Has Occurred!

Call to undefined function split()