Versys Troubleshooting Guide for Charging System.pdf

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Kawasaki Ninja 650R (ER-6F) & ER-6N Resource
Charging System Troubleshooting Guide
By: Kiwi
A number of owners have reported that their Regulator/Rectifier (R/R) have
failed, often this was preceded by a headlight failure and a flat battery leading to
starting issues. Troubleshooting found that not only had the R/R failed but in
some cases the R/R electrical connector had melted with some pins showing signs
of corrosion. The headlight issue was later traced to the headlight relay.
Troubleshooting Index
1.
2.
3.
4.
5.
6.
7.
8.
9.
System Overview
Components and Locations
Circuit Diagram
Common Problems and Remedies
Battery Checks
Rotor/Stator Checks
Regulator/Rectifier Checks
Regulator/Rectifier Connector
Headlight Relay
Tools Required
•
•
Digital Multimeter and test leads with a male & female spade fittings
Tools required for access (spanners, allen keys, sockets and screwdrivers)
Charging System Overview
In simplified terms the Ninja 650R (ER-6F) and ER-6N uses a stationary Stator
Coil mounted to the left hand crankcase cover, it sits inside the flywheel Rotor.
The Rotor has magnets so that when the engine is running these rotate around
the Stator producing alternating current (AC). The Stator is wired in such a way
that there are actually 3 circuits which produce a 3 phase AC output voltage.
This Alternator (Rotor/Stator) setup is connected to a Regulator/Rectifier (R/R) by
3 wires. The R/R rectifies the AC current by using 6 diodes (2 per phase) and
converting it to a useable direct current (DC). The more complex part of the R/R
is the regulator section, it regulates the higher DC current down to provide a
steady 12-14 volts DC. The process in simplest terms monitors the output
voltage and "shunts" (partially diverts) the excess portion to ground through a
“load”.
The R/R has a lot of current constantly flowing through it and the excess voltage
is being diverted to ground through the “load” so the R/R gets very hot in the
process. The construction of the R/R is all about dissipating this heat through the
heat fins on its exterior.
Kawasaki Ninja 650R (ER-6F) & ER-6N Resource
Components and Locations
Stator – removed
Stator – mounted in left hand crankcase cover
Rotor – left hand crankcase cover removed
Kawasaki Ninja 650R (ER-6F) & ER-6N Resource
Regulator/Rectifier – below seat left hand side
Relay Box – under fuel tank
Relay Box
Kawasaki Ninja 650R (ER-6F) & ER-6N Resource
Battery – underseat (black terminal –ve) (red terminal +ve)
Circuit Diagrams
1.
2.
3.
4.
5.
6.
7.
Ignition Switch
Alternator
Rectifier / Regulator
Water-proof Joint
Main Fuse 30 A
Battery 12 V 10 Ah
Load
Wiring Colour Code
BK
Black
BL
Blue
LG
Light Green
PU
Purple
Y
Yellow
BR
G
O
R
Brown
Green
Orange
Red
GY
LB
P
W
Gray
Light Blue
Pink
White
Kawasaki Ninja 650R (ER-6F) & ER-6N Resource
Worth noting is that all the wiring diagrams available for all models of the Ninja
650R, ER-6F and ER-6N refer to the three AC wires coming out of the Stator to
the R/R as black when in fact they are white.
Common Problems and Remedies
Failure of the Regulator/Rectifier (R/R) is often first evidenced by a flat battery
and starting issues. Troubleshooting should always start with the battery.
Make sure you have a good battery. A bad, old or dead battery will load down
the charging circuit until it overheats and dies. You know when you put a dead
battery on charge and it pegs the battery charger ammeter? Well that is what a
bad battery is doing to charging components on your bike.
Having said that. Numerous posts on internet forums with this fault have
indicated that more often than not a failed R/R is the culprit. This is often found
in association with corroded or damaged pins on R/R electrical connector or loom
plug pins. It may be that these are just the weakest link in the chain.

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