Yamaha CS5

[Johnwebley]

Interesting morning

Thought I would see what the control box did,

According to manuals,the centre unit is a cut out,

The big one on the end is the starter solenoid,

Other voltage relay

So with the engine running at fast tickover, about 1700

I pressed the voltage relay switch, nothing happened,

Then the middle one

Charge light out,

But about 4 seconds later, the main/only fuse blew

Time to ponder again

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[Johnwebley]

still having charging issues,


  after a little running,the charge light does dim,but never fully goes out,

   got another test to check,


  then a possible  stator rewind?  or Rotor,,or both,

  but the other alternative is fit VAPE electronic ignition and generator,dowside is you lose the electric start,

  more details  soon

[Skoti]

Fitted VAPE about 10 years ago to a 1942 NSU and a Jawa 350, it's quality kit and has been absolutely trouble free.
But not cheap especially for the NSU 125ZDB.

But I'm aware you have problems with your ankle so perhaps electric start is important?

 

[Johnwebley]

I don't really need to kick start it
I can just lean over the seat and push the lever with my arm

Starts easily enough

But I like to press the button!!

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[Bryanj]

Let me have a ponder on some test for you Ted before you remove anything

[Johnwebley]

Just visited a local electrical rewind specialist

He suggests clean thoroughly,

Current can leak away using debris from the worn brushes

More news in a few days

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[Bryanj]

If you can get it Armaclean is best or carbon tetrachloride but i think that is now designated as a "nasty"

[Johnwebley]

an interesting morning,

cleaner spray brought up everything like new,

 rotor segments all good,no leakage to earth

  cleaned the stator and brushs

  brush 1 and 3 seem to be the power ,nice and clean,no leakage to earth,brushes 2 and 4 are earthed,so not so critical.


  started again,guess what,no change,still no charge

[Bryanj]

Does the electric starter work?

[Johnwebley]

yes,

  but it seems slowish,

  but I am comparing it to the 500 and 200,which have different systems,


   the only electrical thing that really needs replacement is the ignition switch,it has been knacked ,with the centre core removable and all the pins missing


 would that make a difference?  my thoughts are it only turns a  contact unit to switch it all on

[Bryanj]

Just the lock part will make no difference, from what you described the problem is the regulator/cut out box, i have been trying to work out a test for it but having been away for 3 weeks work is hard!

[Bryanj]

John try this
aircooledclub.com/manuals/cs3b.pdf

I have screenshot the reg part and will read testing at work on sunday and get back to you

That should be aircooledrdclub.com/manuals/cs3b.pdf

[Johnwebley]

I have tested the regulator,

No current being fed to activate the generator,

So I have sent it off to a place in Lincoln,
He specialises in old dynamo and control boxes,

Strips them out and converts them to solid state,

With updates, such as reverse polarity protection

Also will keep the electric starter

I also have been busy, putting a new rim on the rear wheel,

First ever wheel build

Also before and after wheel

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[Bryanj]

Well done Ted, just takes patience mate, i would think the reg is a corroded contact of siezes pivot but if the man can convert it reliably thats good

[Johnny4428]

Very satisfying to build these. The truing is therapeutic.