anything higher than 1/3 throttle no power

[thatkid]

You already have the new VR if it's finned, so no upgrade needed.

I'm not certain (I've never Red lined mine) but I think the TCI has a inbuilt electronic rev limiter, or there is some kind of rev limiter built into the bike.

One of the Grey wires from the TCI connects to the Tacho, I.E. the TCI feeds data to the Tacho. Does a rev limiter cut the engine, then when a safe RPM is reached the limiter deactivates? I ask because the last time I dealt with that kind of issue was on a customer's 2.8i Ford Capri. The limiter was cutting in too early, they had mechanical Rev limiters in the rotor arm driven by centrifugal force, it was a simple fix, but that was in the early 80's.

EDIT, this is an entire guess. Is the Main Relay (It's smaller than the Flasher relay and it's connector has 10 wires) fastened secularly? Remember that relay powers the TCI. The pins/prongs could be corroded, or one of the wires could be breaking from it's Female spade. I recently had a wire snap from the Main Relay connector.

[jmcmotorsports]

ok i wasnt sure if it was like an r6 vr or anything. but everything has an electronic rev limiter but it is at a much higher rpm than what mine is cutting out at. i can be going about 60mph and try to reach 65-70 in 5th gear and it hits the limiter.

i did check the battery charging voltage with it grounded where i had it, at idle it was charging at 12.4vdc. at about 4k rpm it was about 12.5vdc. i grounded the vr to the battery and at idle the charging voltage was about 13.6vdc. so i believe i may have it straightened out, but its raining today so ill have to wait for a nicer day to test ride and see if it really helped.

[thatkid]

You do know 12V batteries are actually 12.6V, 6 cells all of which should produce 2.1 V = 12.6V? so 12.5V @ 4k rpm was very low. Hopefully that was your issue.

Good luck
Mal.

[jmcmotorsports]

Yes I do know it should be a little bit higher but its not as bad as some I have seen, I cannot keep it on a battery tender as I wish I could but for not being ridden on a daily basis its not horrible at that.

[thatkid]

i did check the battery charging voltage with it grounded where i had it, at idle it was charging at 12.4vdc. at about 4k rpm it was about 12.5vdc. i grounded the vr to the battery and at idle the charging voltage was about 13.6vdc. so i believe i may have it straightened out, but its raining today so ill have to wait for a nicer day to test ride and see if it really helped.

Wait I think I've dropped a bollock here!!

You did clean the VR,s connection's before you relocated the ground wire? A poor ground IMO should not only over charge the battery, It will kill your electrics!!!!

I.E. a poor ground on the VR negative wire should NOT cause a low charging voltage.

I have trouble understanding, the American use of English, and probably visa versa!!!

Here is my interpretation of the Voltage Rectifier/Regulator.

Wait im looking for older posts I'll update ASAP

Can't find it but it's there some where.

The VR or "Voltage Rectifier/Regulator performs two tasks

1. The stator/alternator/magneto (dont really know what you call it) produces to my knowledge 40 to 60 Volts AC. AC voltage WILL not charge a battery, DC voltage is required.

The rectifier VIA a three diode pack, rectifies the AC output to DC, have you ever used an oscilloscope, and compared AC voltage to DC?

2. The Regulator limits the charging Voltage to a safe limit. I.E. to charge but NOT overcharge the Battery, any excess voltage is leaked to ground. The old VR utilised it's alloy body (IMO a very bad design) The very much improved finned VR utilises it's ground wire.

Therefore a poor ground should overcharge the battery.

I did find 1 recent post that might interest you, and may explain things better.

viewtopic.php?f=8&t=6733&start=0

Ignore my comments, Please focus on "reelrazor's" input IMO and probably many others here, that guy really know's his stuff.

[thatkid]

Yes I do know it should be a little bit higher but its not as bad as some I have seen, I cannot keep it on a battery tender as I wish I could but for not being ridden on a daily basis its not horrible at that.

Quite obviously SIR you know something that I do not. my knowledge is apparently far inferior too yours.

Last week or so, I had issues with my bike (which I check regularly), that has been stood un ridden since 1st of May 2010, the charging voltage was something like 13.3 volts @ 3000 RPM, (which is low) I quickly solved the issue with no help from anyone.

I want to know your secrets of not riding for a few days and expecting a charging voltage sooooo low, to be adequate?

Thank You.

[jmcmotorsports]

Well there is no need for the sarcasm. I did not mean to discard any of your intelligence about the bike, I was only stating what I did know and what I have checked on my bike. I did not say it was optimal, only that it was better after I re-located the ground. The bike may not be perfect, because after all it is almost 20 years old so things may be worn out.

I am new to the forums, and new the streetbikes I have worked on dirtbikes and cars here and there. But I don't know everything that's is why I am on here trying to solve this problem. Thank you for your input, but obviously I was not trying to shut down what you know or don't know, just what I have seen.

[thatkid]

I apologise SIR, I'm a Qualified motor (car) technician. I find it quite rewarding helping others that is my nature. I know no one knows everything, only an idiot would claim that.

Usually when anyone disregards my advice, (it happens in real life not only on this and other forums, and not only to me) I zip it and ignore them. let them waste their time, and hard earned cash (which does not make me happy), some consider free advice to be useless, therefore ignore it.

Your comment indicated to me that you thought I was talking out of my backside. If that was not the case again my sincereness apologises.

12.5 Votls @ 4k RPM is not only low it's very inadequate.

[thatkid]

The Main relay performs several task's. Some of which are, it manages the safety switches, supplies power to the TCI, and houses the fuel pump

I was wrong.

I'm studying two wiring diagrams, the easy to follow diagram here , My 600 has different wiring, single headlight, no running lamps, and other difference's.

The second diagram does not match mine. The Main relay does not power the TCI. not on mine. I've rechecked the digram in the wiki. The main Relay does not power the TCI.

[jmcmotorsports]

gotcha, thanks. i have not had time this week to work on it or ,much less take it for a ride to see if the problem is still there. as soon as i can im going to check out the charging system and electrical and see if it still is cutting out.

[yamaha_george]

Ok,
so sticking my head above the parapitt, 12.4 volts at 4K RPM is a rubbish charging rate! at 3K it is supposed to be 13.4 / 13.9 according to memory and no more than that !

When replacing the original VR with a late model it is easy to not put the grounds in the right place, I seem to recollect that other people have had issues with this.
see:-
http://www.saltmine.org.uk/fzr/vr.html for how I placed my grounds which seem to be still working 2.5 years later:-}

[thatkid]

All manufactures state different tolerances, why? They don't always use the same manufacturer for all of their components. They buy the cheapest available too them at any given time. They save say 1p on any part, then produce 1 million cars/bikes, it's all about profit margins.

I'm not disagreeing with You Geo, The higher the charge rate, then I would start too worry. In my experience the safe charging rate for a 40 amp hour car battery is 13.6 to 14.4 Volts.

In 1991 the wife had a mint condition 1979 Ford Fiesta, No holes no rust. The battery died so I replaced it, the thing leaked acid corroding the inner wing. The fault on the battery was, a faulty seal between the bottom case and the top, it was not overcharging. I took the car too where the battery was bought.

Obviously they checked the charge rate, it was something like 14ish volts, sorry Sir the battery is over charging not our problem!

Me. Please check your data book. The battery was replaced.

As for the crap old VR they are also used on 125 motorcycles, with no electric fuel pump, and less electronics

Read this Ebay listing!
VOLTAGE REGULATOR for YAMAHA FZR 600

[jmcmotorsports]

Thanks. Would the vr make the odd charge rate? The only question is why it charges at a proper voltage at idle but not while revving.

[thatkid]

There's a charging system flow chart Here

Keep us updated
Good Luck

[jmcmotorsports]

so i checked everything and it seems to check out right, i cleaned up some of the wiring and the vr ground. at about 3k have a 13.4v charging rate. still have yet to take it for a test ride and see if that fixed my original problem, but will keep updated. thanks for all the help!