Info Manual

We all know that small bikes charging system is made up of only a Half wave ac to dc conversion thus making it impossible for the system to give enough juice out from the stator to charge batteries at low rpm...To compensate for a FULL WAVE rectifier be installed on this system, we need to do some modifying to the stator,

the picture shown uses the stock configuration of a Half Wave system with an AC lighting coil present for headlight connection center tapped to the whole winding of the stator. One end of the coil is connected to chassis ground. I order for this system to give way for a FULL WAVE rectifier, the grounding system must be omitted and center tapped connection for headlight must be removed as shown on the next picture below.





the headlight will be redirected to the battery by cutting the yellow line of the AC lighting coil from the Stock regulator/rectifier, so that the headlight ON off switch as well as the HI/LOW system will still be used without any rewiring that headlight path.







ADVANTAGES of this system than the latter.

with full wave regulation you have almost twice usable dc power (and cleaner) than with half wave
last , cleaner regulation with the sens wire, if well used, it deliver more power if their is a drop (big consumption) than the other fixed simplier one where lighting often drop
and better protection for you electronic again drop or over charge

Shogun FL125 charging system is actually the same as shogun FD125XRM. This article will show you how to test your electrical preferably the CHARGING and lighting system.













CHARGING and LIGHTING wiring diagram



Here i'll be giving you where and what to check if you are having problems with battery charging and lighting problems. You'll be needing a multi meter a digital with a diode test to perform troubleshooting your own bike.

LOCATION of SHOGUN FL125 Regulator 


The regulator is located in front when you take off front cover, shown in number 2 with part number SH672, remove the connector shown in number 1, set your multimeter to diode test and follow the next picture for the right data.

You dont need to turn your ignition, this is to test the leakage on your Regulator.







The reading of all the test must be close to what is written above, if there is a short or almost 0 on the digital read out then the Regulator is defective.

If all test of the regulator is OK!! we then proceed with the generator system and lighting coils resistance and voltage.

GENERATOR Resistance and Voltage check

Set the digital multimeter in resistance range.


Disconnect the  black connector as shown to perform resistance and voltage check, this is the connector of the generator, other is for the pick-up coil and ground.














for lighting coil resistance, connect the multimeter probe to Y/W (yellow with white strip wire) and to ground..

The reading must be
0.4 - 1.0 ohms

and for the charging coil, connect probe to W/R (white wire with red strip) and ground.

The value must be
0.6 - 1.2 ohms


VOLTAGE CHECK

NOTE: 
This check must be taken with safety because we are talking about AC voltages here. No wires from the generator must not touch any metal on the chassis. Youll be needing to crank the engine and rev to 5000 rpm to test the generator output.



Multimeter is set to AC voltage range. connect probes as shown, AC do not have polarity so either way..

W/R and ground rev at 5000 rpm must read
50 volts AC or more but no more than 100 volts

Y/W and ground rev at 5000 rpm should read
40 volts AC or more but not more than 80 volts

readings not close or lower than the specified value means there are problems with the generator windings, either there are short due to exposed wires inside and or the skin coating of the enamel wires of the windings are already exposed to the oil.

GOODLUCK with the test.

UPDATED

Full schematic wiring diagram of this bike can be found here

SHOGUN COMPLETE WIRING DIAGRAM

Motorcycle voltage regulator commonly uses shunt type in order to control the output of the generator. Shunting the winding to ground is easier than controlling the output of the regulator by those series type.

Circuit on the left is still a shunt regulator controlling the windings, with parts easily obtainable from your local electronic supply stores.



CIRCUIT DESCRIPTION:

D2 and D1 are the SCR that will control the voltage output of the generator, as the rpm of the engine rises D4 and D5 will convert the AC to DC and shall charge the battery, as the battery is being charged, it is been monitored by Q1, R1, D3 and R4 that comprises the voltage threshold of the entire unit and must be adjusted to 14.4 volts cut off. When the sense circuit seen the voltage rises, Q1 will be turned ON and current will then flow towards the gate of the two SCR turning them on thus shunting the windings not to generate more than needed, protecting the battery from overcharging.

NOTE that this circuit do not have a HEADLIGHT controlling device and or headlight regulator, its for charging battery only on motorcycles with stator.