The relay regulator, or voltage stabilizer, plays important role in the operation of modern scooters, the main task of which is voltage stabilization. At a moped speed of 60 km per hour, the generator is capable of generating voltage up to 35 Volts, and without its stabilization, this can lead to failure of all the electronics of the moped, including the battery. The article will tell you what a voltage regulator is and how to check it on a scooter.

Four-pin voltage regulator relay for scooter

What is a voltage regulator used for?

The relay regulator stabilizes the voltage of the scooter generator at the right level, not allowing him to increase or decrease the indicator more or less than the norm. This prevents horse racing onboard voltage go beyond the established limits (depending on the boards this is 12-14 V) and ruin the work of consumers whose service life is designed to be no more than 13 V.

That is, this part takes on the impulses that arise during the operation of the scooter (turning on the headlights, the starter button) and transfers the resulting thermal shock to itself. In this case, all the heat that could settle on the contacts is generated in it and removed through the device.

In addition to voltage stabilization, the relay also converts alternating current to constant, which is necessary to charge the battery.

Moped manufacturers install charging relays on scooters with different parameters and select them for each individual. Depending on the regulator circuit, the connectors also differ. U Chinese models Usually there are 5 terminals (male), Japanese have 4.

Scheme and principle of operation

The operation of the stabilizer for all models is almost the same and consists in distributing the current supplied from the generator to stabilize it and further distribute it to consumers.

The operation of the stabilizer is almost the same for all models

The main peripheral consumers of the scooter include:

• battery;
• indicators;
• light bulbs;
• sensors;
• enrichment agent;
• other nodes;
• starting enrichment.

How does the stabilizer work? The main principle of its operation is to act as a transformer, which reduces the voltage to optimal level, acceptable for work electrical appliances, and also stabilizes the network and prevents unexpected power surges.

If the relay malfunctions, the scooter’s devices fail, quickly wear out or burn out.

To avoid these problems and their undesirable consequences, you need to know the basics proper operation electrical circuit and voltage components of the scooter (Figure 1).

Voltage relay pinout diagram and wiring for main scooter models

The pinout of the relay regulator is standard for all models of Chinese-made scooters.

Scooter relay-regulator pinout

The stabilizer has an aluminum body and plastic contacts, each of which has its own wire. Each contact has its own wire color. This makes it convenient to connect the device to the wires if the plastic connector is worn out. The wires must be connected to the contacts according to the electrical diagram (Figure 3).

Electrical diagram relay-regulator connections

Signs that a check is needed

If the battery on your scooter often runs out, and it is still quite new, this means that there is a problem with the operation of the relay regulator. As practice shows, it burns out quite often. If the device is faulty, the battery stops charging completely and loses its capacity. This means you won’t be able to start the scooter with a button; you’ll have to start it with a kickstarter.

One more characteristic feature incorrect operation The device may be caused by frequent burnout of incandescent light bulbs. They themselves are durable and have good resource strength, but quite sensitive to voltage changes. This happens because the optimal voltage in the scooter network is considered to be 12-13 V. Increasing this value even by 2 V reduces the service life of electronics and components by 2 times.

The greater the deviation from the norm, the greater the likelihood that something will burn out in the scooter. Therefore, when starting the scooter from the starter due to a power surge and a faulty relay, the bulbs usually burn out.

Signs of a malfunctioning regulator are identical for all models of Chinese scooters. They are especially typical for charging relays for scooters of Chinese models with an engine capacity of 50 cc. Therefore, before making a decision to replace something in electronics, testing systems and devices should begin with the relay regulator.

For all models of Chinese scooters, the symptoms of a malfunction of the regulator are identical.

How to check PP with a multimeter on a moped?

The relay regulator on a Chinese scooter is checked using a multimeter with a voltmeter function. For this purpose, a simple DT-830 (or equivalent) is usually used. It is better to carry out diagnostics and measurement of output voltage with the device removed.

Verification algorithm:

1. You need to unscrew the fairing with the central phase and find on the frame a device with 4 wires: red, green, yellow and white.
2. Then start the scooter and Idling check the voltage: measure it between the green and red wires, setting the multimeter to the maximum value of 20 V.
3. If the multimeter display shows a figure of 14.6-14.8 V, this is normal. For stabilizers on Chinese mopeds, this is the operating standard voltage. If at idle the multimeter shows a value of 15-16 V, this is high rate voltage. This indicates a malfunction of the relay regulator.
4. Then you need to check the voltage supplied to the lighting lamps. An alternating voltage is supplied to the central low beam (high beam) lamp, so the multimeter should be switched to the alternating current measurement mode with a parameter of 20 V.
5. Next, we measure the voltage between the green and yellow wires (green is the general electrical network of the moped). If the multimeter shows a network voltage of up to 12 V, then the electrical appliances are operating without additional load.
6. If at idle this value is 16 V or higher, and with a sharp increase in engine speed it jumps to 25 V, the device does not stabilize the voltage and, therefore, does not work. With such readings, the device must be replaced with a new one.

Using a multimeter, they check the relay regulator on a Chinese scooter

On 4T scooters, the relay regulator is checked using a tester. Typically a mechanical tester is used for these purposes, although there are also electronic models.

In order to take a measurement, you need:

• switch the device to the “KiloOhm” mode and remove the regulator;
• then place the probes on the first pair of terminals (AB). The tester should show a value of no more than 18 kOhm;
• after this we change the position of the probes on the terminals in reverse direction(VA) and measure the voltage again - the arrow on the device should show 0;
• then we install the probes on the next pair of terminals (SD) and measure the readings on this pair;
• swap the probes (DS) and measure the indicator again;
• the remaining measurements have no contact and are not checked. The indicator when checking them should be zero.

In this way, regulators are tested on popular Japanese models with small engine capacity from brands such as Honda (Leard, Dio, Tact), Suzuki, Yamaha.

Replace faulty relay regulator no problem on a scooter

How to replace a faulty relay regulator on a scooter?

If there is no power supply to the battery contacts charging current If the generator is working properly, you need to change the stabilizer. Replacing it yourself is not difficult.

To do this you need to do the following:

1. Place the scooter on the central support.
2. Find the location of the device in a specific moped model. If you can’t find it right away, you can use the instruction manual.
3. Dismantle the cladding. Depending on the moped model, the stabilizer may be located on the front (under the front plastic), in the rear, or under the seat. In this case, the underseat space is removed along with the seat.
4. Unscrew the device from seat while maintaining the fasteners. As a rule, the relay is attached to the scooter frame with a bolt, or less often with a self-tapping screw.
5. Disconnect the connector and secure the new regulator with the fastener. Installed device must have a pinout and connector similar to the one replaced, and be suitable in terms of parameters for this particular scooter model.
6. Connect the relay-regulator on the scooter to a standard connector and assemble the remaining spare parts in the reverse order of disassembly.

How to make a relay regulator with your own hands?

To make a relay regulator with your own hands, you need a diagram and a little knowledge. The basis of the model homemade regulator The principle is based on disassembling the generator and removing a separate end of the wire from ground.

As a diagram, you can take the relay-regulator connection diagram (Figure 3), and on its basis assemble a single-phase generator.

To collect the stabilizer you need:

• disassemble the generator and remove the stator from the engine;
• then you need to unsolder the ground from the generator, solder a separate additional wire for the winding to it and bring it out. This wire will be one end of the winding. The second end is the generator wire;
• After removing the wires, you need to reassemble the generator in reverse order.

With this device, the generator has 2 wires (there should be 3 in total). You can connect the stabilizer according to this scheme:

Do-it-yourself relay-regulator manufacturing diagram

At the end of the process, you need to connect the yellow wire from the old regulator to the “+” terminal in order to obtain a constant voltage on the sides of the network. Check the resulting voltage regulator on the scooter. At this point, the process of creating a homemade device can be considered complete.

The relay regulator is a very useful thing and necessary for the normal operation of the moped. However, it requires attention and constant monitoring of its work. Therefore, if the device fails or its performance is unsatisfactory, it is better to replace it with a new one, the cost of which today ranges from 300 to 500 rubles.

How to check the voltage regulator of a scooter for serviceability - theory and practice

Voltage regulator, or whatever else they call it, relay regulator, has a clear purpose on modern scooters. The voltage regulator stabilizes the current supplied from the generator so that it can then be distributed to the main consumers, such as light bulbs, sensors, relays, batteries, indicators, starting enrichment, etc. Simply put, the voltage regulator on a scooter is a kind of transformer in electrical network, which lowers and stabilizes voltages to a level that promotes the normal operation of all devices and has certain limits beyond which voltage surges are unacceptable.

Let's look at an example when The scooter light keeps burning out.. We buy a new one, then another one, without thinking that in fact the service life of a regular incandescent light bulb on a scooter is quite long, and the reason frequent replacement lights in the voltage regulator.

The principle of this is quite simple. Let’s assume that any electrical appliance on a scooter is designed to operate on 12-13 V AC power. In this situation, any device will serve its allotted time without any problems. If the voltage increases, even by 2 V, the service life will be halved. The higher this threshold rises, the less chance any electrical appliance has to work properly and for a long time. This is obvious, and therefore, in these situations, you immediately need to check the voltage at the approach to electrical appliances.

Let's look at the pinout of the voltage regulator of Chinese scooters and mopeds:

For each contact, the color of the wire that fits is indicated. This is very useful to know, especially if for some reason the plastic connector itself has broken and you don’t know what to connect where, or something has come unsoldered. There are a lot of questions like this, so I decided to post them so that they don’t ask anymore.

Now let's look at the circuits and pinouts of the regulators on Japanese scooters:

Here we see the main pinout, as well as the wiring diagram. I think everything is very clear.

How to check the voltage regulator of a scooter.

For this we need a tester. In our case, it is mechanical, but you can also use electronic. The main thing is that the tester shows correctly and does not represent a cheap toy.

We will carry out measurements on the regulator of a Honda scooter. These are also used in most Chinese scooters and mapeds. So let's switch measuring device to “KiloOhm” mode. We remove the relay regulator and begin measurements. For convenience, the contacts are indicated by letters:

We place the probes of the device on terminals AB, and the tester shows 18 kOhm.

After this, swap the probes (BA) and look at the readings; the arrow should remain at zero. It is important.

Now we install the probes on the LED terminals and observe the reading of 33 kOhm.

We change places on the DS, we get 42 kOhm.

All other measurements have no contact and are not called. The indicator should be zero.

This way you can check the health of the scooter's voltage regulator (in our case, this is Honda scooters Dio, Honda Lead, Honda Tact and scooters with similar regulators). Radically other devices may differ in readings, so this must be taken into account.

No matter what kind of electric scooter you buy, you need to maintain it in good working order so that you can enjoy it for a long time. Maintenance and testing of a scooter's electric generator is very important, so you need to know how to properly diagnose and Maintenance. Electric scooters and motorcycles require virtually no maintenance. In this article we will talk about the main ways to check functionality electric generator.

Most electric scooters use a hub motor or electric motor that is conveniently integrated into the hub of the front or rear wheel. This does not change the basic design of the device. Since the motor is attached to the wheel, it can move that wheel very efficiently. The generators are easy to install and easy to access for maintenance and repair. When you turn off the electric scooter to return to running mode, the hub functions just like a traditional wheel hub, which connects the tire, rim and spokes. To keep your electric scooter running, you need to regularly maintain your device.

Hub engines have no disadvantages. First, they add extra weight to the wheel they power. And because they require additional wiring to deliver power, using wheels and changing tires is difficult. With this in mind, you will need to properly maintain your device.

Hub motor cones come in a variety of designs, and there are differences between designs. The smaller geared motor offers an increased rpm range but less power. Gear-type motors are usually large and heavy, but they provide more torque and power to an electric scooter. They are more efficient than gear motors. However, no matter what the design of the generators is, the principle of their operation is the same, which means the maintenance is the same.

Taking care of your electric scooter is key to maximizing the performance and usability of parts and components, especially engine components. If you know what kind of motor your device runs on, this article will help you know how to properly test your scooter electric generator.

Where should you start first? Check everything electrical connections on your scooter. Most of them can be found in the battery compartment. Make sure they are all tightly connected to each other. At this time as battery pack your scooter in automatic mode will check the main and individual connections to the batteries. Bundles of wires should not hang freely.

Usually the battery compartment on a scooter is located at the bottom of the floor

Test the generator by making a direct connection to the battery. You will need to find an insulated wire to perform this procedure and cut 2 pieces approximately 20cm long.

Setting up and testing the scooter

Check the power interrupt switch. This safety feature "interrupts" engine power when you apply the brakes. If your scooter does not work after adjusting the brakes, then the problem lies in this unit.

Adjustment procedures may vary depending on the scooter model. You can usually loosen the brake adjustment tension by turning the brake adjuster built into the handle toward the lever. This releases the tension on the adjustment and safety switch. Check the owner's manual or contact the motor manufacturer.

If this setup doesn't work, there is an easy way to test the generator. Disconnect it from the controller, then try to start the scooter. If the problem is with the switch, then the scooter will only work when the brake lever switch is disabled. Make sure the power switch is turned on.

If the scooter is using a fuse, look at inner part fuse to make sure it doesn't burn. The fuse may need to be removed from the scooter and held up to a light source so you can determine whether it is blown or not.

fuse in scooter

For scooters that use an automatic fuse, press or flip the automatic switch to check its functionality.

Automatic power switch

Perform a test using a multimeter. Sometimes fuses burn out in a hard-to-reach place. Also, circuit breakers can mechanically reset but still not work. Checking the integrity of a fuse or circuit breaker using a multimeter - The best way determine whether they work or not.

Also try charging the battery for 8 hours. Electric scooters that have not been charged for more than 3 months will have their batteries partially discharged. Try charging the battery for 8 hours and then see if that helps.

Remove the generator base plate or cover and look for any burnt or melted wires, wire connectors, or electrical components. Also look for loose, disconnected or damaged wires or wire connectors. Pull and push on all individual wires and wire connectors to ensure they are not loose.

Sniff the engine speed control to make sure there is no burning smell. Any components that appear burnt or melted, or have a distinctive odor similar to burnt plastic, are almost always defective and should be replaced. Motors that smell burning should be replaced to prevent damage to the speed controller. Burnt or melted wires or wire connectors indicate overheating of the motor, which can cause the plastic insulation to melt the motors' electromagnetic copper wire windings.

If the insulation melts from the copper windings, a short circuit will occur, which will lead to complete breakdown of the generator. A short circuit can also burn out the speed controller by giving it too much resistance, causing it to work too hard to the point of overheating.

Data on the health of electric motors is, in most cases, obtained using a braking test. Power consumption is calculated based on current and voltage. During the test procedure, the engine is freely accelerated and stopped to no-load speed. From the moment of inertia and acceleration, the engine torque is calculated and the power at full speed is set. Since the entire measurement time, depending on the size of the engine, is usually less than one second, the engine does not have time to warm up. During this time, it remains at room temperature.

Check the battery with the scooter running. If the scooter is running, you can perform a battery test on it by fully charging the battery and then checking how long the battery lasts. Most electric scooters will have a range of about 30-45 minutes. If the generator runs for less than 30 minutes, it is worn out and may need to be replaced. If the generator runs less than 20 minutes, it is moderately worn and should be replaced. Severely worn generators will only run for 5-10 minutes.

If you have a multimeter and the scooter is in working order, you can check the load on the battery pack by fully charging the battery. Then lift rear wheel, connect the multimeter to the battery and give the scooter full throttle while engaging, but do not lock rear brake. When you apply the rear brake, the battery will be "stressed" and you can then read its voltage to determine how much it drops. If the battery is in good condition, the voltage only drops a few volts, however, if the battery is worn out, the voltage will drop more rapidly.

Batteries are an integral part of the operation of an electric generator. You won't get far without good batteries. Always use a charger recommended by the manufacturer. This charger must have indicator lamp or a sensor that will tell you when the battery is charged.

Do not leave the battery in charger after charging it. This may damage the battery.

If you notice that your battery no longer holds the same amount of charge that it used to, this means that your battery is getting old and you will need to replace it. Pay attention to corrosion and any chemicals that may be leaking from the battery. If you notice any leaks, replace the battery immediately. If you see corrosion on the battery terminals or connectors, clean the corrosion. Remember to charge the battery after the battery has cooled down. This will help extend the battery life.

Scooter alternator voltage test

If you have a multimeter, you can check the output voltage of the generator. U good batteries the voltage will exceed its rated voltage level even if it is completely discharged and allowed to sit for several minutes or if it is in storage.

If the battery does not recover above its rated voltage level within a few minutes after being discharged, this indicates a faulty or worn-out battery. When the battery is fully charged and its voltage is below the rated voltage level, this also indicates a faulty or worn-out battery. Good rechargeable batteries for scooters will return above their rated voltage level within a few minutes of starting the scooter.

Look for any burnt or melted wires or wire connectors on the speed controller. If any wires are burned or melted, the speed controller may be faulty. Smell the speed controller for any burning smells. If the speed control smells, it is almost always faulty.

Speed ​​controller

If the speed controller doesn't have burnt or melted wires and doesn't smell, it may still be faulty. Check all other components electrical system around the speed controller and use the elimination process to determine whether the speed controller is working or not. Speed ​​controllers are too complex to be easily tested. Usage professional diagnostics is the best way to determine whether the speed control is working or not. If all other components of the electrical system are fine, but the scooter does not work, this indicates a faulty speed controller.

You can also see several video

The scooter generator is one of the most important details scooter, its malfunction indicates the impossibility of continuing movement, the spark simply will not appear. But if you doubt whether your generator is working or the reason for the malfunction of the scooter is in another part, it is strongly advised to check the generator. Many people don’t know how to check the generator on a 4t scooter, because this relates more to electrics, which scooterists hardly understand. Also, the verification problem will be in the absence of the main tool - a multimeter tester.

Experts identify several reasons for generator failure:

• short circuit formation;
• mechanical failure or wire breakage;
• significant reduction in rotor magnetization.

Basic faults

Before checking the generator for serviceability, we will consider the main faults. Practice shows that the generator breaks down most often on Chinese scooters, where the most frequent breakdown is the rotor losing magnetization. The rotor often loses magnetization precisely because the scooter falls, that is, there is a direct impact. Also, if there is a nearby magnetic field, the rotor discharges.

Checking with a multimeter

To check the charge on the generator, you will need to use a proven method; the main task is to find out the output voltage. First of all, completely disconnect the generator from the scooter, then use the control device and start the engine. After starting, you can check the output voltage; the working generator should show at least 5V with the engine running.

The second stage is checking the output voltage of the switch; for this you will need a multimeter. The testing process begins by connecting the commutator to the generator stator, this is done using wires from both parts. Then you need to disconnect the wire related to the switch block from the ignition coil winding terminal. The next step is to connect two terminals - one goes to the engine ground, the second to the main wire on the ignition coil. This main wire is connected to the commutator.

After this, you will have to set the voltmeter to the main mode " D.C."and crank the engine with the kickstarter. By these actions we can find out the output voltage of the switch to the ignition coil. Then connect the switch wire to the coil. Under normal conditions, the output voltage of the scooter should be 200 V. For many, such a test may seem too complicated, because most of the terms are unfamiliar, and not everyone can use a multimeter, but if you really want, you can try and check the generator on a Chinese scooter.

Voltage check

Using a multimeter, you can find out the presence of voltage and its indicators, so you will have to start the procedure by removing some parts of the plastic located in the engine area. On the scooter you will have to find a large bundle of wires, which is located on the engines. Find the wire that should connect to the generator. The next stage is measuring the parameters of the circuit, the main task of which is to power the generator coil with electricity. Important: before this test you will have to disconnect the wiring from the generator, after which you can check the resistance. In normal operating condition, the generator should produce a resistance of 80 to 150 ohms. Deviation from the norm indicates a malfunction of the generator and the need to replace it. In some cases, the presence of incorrect resistance lies in the wiring, which is faulty. This can be determined by removing the generator and checking the coil resistance separately; if it gives optimal data, the reason is in the wires, in particular their short circuits.

Detecting the above faults is not an easy task; most scooter owners are not able to check the generator for serviceability, which is why they turn to specialists. At financial possibilities easier to buy new generator, so you decide how to solve this problem yourself.

Voltage regulator or as it is also called a relay regulator. This piece of electrical equipment is very important and the longevity of the battery and other electrical appliances depends on it. The relay functions as a voltage stabilizer at the level that the generator produces, then this voltage goes to all the scooter devices that use it.

If the voltage regulator was faulty or missing from the scooter, the voltage would jump and all the devices would quickly burn out. The regulator keeps the voltage within certain limits, preventing it from rising and falling too much, usually within the range of 12-14.5 volts. For example, incandescent lamps suffer significantly even from an increase in voltage of 2 volts.

The generator can produce 35 volts, and the regulator resets this voltage to 12 volts. To charge a scooter battery, you need direct current; it is the regulator that turns alternating current into direct current. Therefore, you need to look at the condition of the scooter’s voltage regulator very carefully so as not to cause trouble.
One of the ways to understand that the relay regulator has failed is that the light bulbs quickly burn out. They themselves have a fairly high resource and durability, but at the same time they are sensitive to voltage drops.
By the way, when starting the scooter from the starter, a strong surge in voltage occurs, which can also cause harm, but the regulator on the scooter again corrects this situation.

Different scooter manufacturers supply different relay regulators, since each model requires an individual one. Depending on the voltage regulator circuit, the connectors may also differ.

The voltage regulator relay on a Chinese scooter differs from the Japanese one even in the number of terminals. So, in Chinese there are 5 of them (dad), but in Japanese there are only 4.

But general principle The operation of the voltage regulator is almost the same in all and performs the role of switching voltage using a powerful thyristor, turning on and off the voltage from the generator.

Regulator diagram on Japanese scooters:

How to check the voltage regulator of a scooter?

To check, you need to stock up on a multimeter that has a voltmeter function. It is needed to measure the voltage at the output of the voltage regulator.

To measure the voltage, you first need to get to your destination. To do this you need to remove the front fairing. As a rule, it is fastened with several nuts and rivets (for example, Honda dio has 3 nuts and 4 rivets). We remove the fairing carefully, it is easy to damage. There we need to find a small box in which there are 4 outputs (some scooters have 5 outputs). The outputs have the following colors: green, red, yellow and white.

In order to measure the voltage, the scooter must first stabilize in operation, that is, the idle speed must be stable. You can put it on the step, start it and wait for it to stabilize. If, or does not hold idle, then read the article:. If everything is fine, then you need to measure the voltage between the red and green wires. We set our measuring device to 20V, measurement mode DC voltage. If the voltage is within 14.6 - 14.8 then this is normal voltage relay regulator. If the regulator is faulty, then this value can fluctuate even by 5V or more in any direction. If the value is less than 14.5V, or exceeds 15V, then the regulator is faulty.

Now you need to check the voltage supplied to the lighting. Since alternating voltage is supplied there, we set our multimeter to measure alternating voltage 20V. To measure the voltage supplied to the lighting, you need to measure it between the green and yellow wires. As a rule, the norm for lighting is voltage in 12 volts, most incandescent light bulbs are designed for this voltage. Allowed + – 0.5 volts. Do not forget that the scooter operates at idle and if you add speed, the voltage will rise, but it is not permissible for the voltage on the regulator to rise to 13+ volts. If the regulator is faulty, the voltage may rise higher. For example, up to 15-16V, but even 13 volts of voltage is harmful for incandescent light bulbs. The regulator is clearly faulty. Especially considering that it's on idle speed engine.

If you see that the voltage regulator is faulty, you need to urgently replace it. Otherwise, very soon other devices will be added to it that simply could not withstand the high voltage.

A 4t scooter voltage regulator relay can be bought for 500 rubles.

If you don’t understand what and how to check, or have additional questions, you can ask them in the comments or find the answer in the video:

Do-it-yourself voltage regulator for a scooter

You can make a relay regulator yourself; this requires a little knowledge and a scooter voltage regulator circuit. We will make a voltage regulator for a Chinese scooter with our own hands. The cheapest option is to use a shunt voltage regulator. The caveat is that for proper operation you need to disassemble the generator and remove the wire from ground with a separate wire.

It was decided to make a voltage regulator with your own hands for the reason that Chinese analogues so lousy that there are simply no words. Look at the photo of the Chinese voltage regulator circuit:

We will assemble a single-phase generator according to this circuit:

In order to make a relay regulator, you must first disassemble the generator and remove the stator from the engine. Now we see this picture:

The photo shows a mass that needs to be unsoldered, and to it we need to solder a separate wire to the winding. After which it needs to be taken outside. This wire will be one end of the winding. The other end is the white wire.