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Discussion Starter · #1 ·
Hi everyone, bought the worlds worst/abused 2012 R125 as a first bike, built it up and repaired a lot over the last four months, thought I was there and now this (although I think the error was there I think just undiscovered...anyway). Its had an intermittent code 46 error but I though it was initially due to the battery originally in it being knackered.

I put a new battery on the bike as it had a bigger (physically) battery that had the tray mashed up to make it fit by the previous owner, stock spec gel battery put in along with a new lower section to replace the battery tray. since the rebuild and after the crappy weather it had a first run Friday...all good but error 46 came up again, only out for 30 mins. Went out again today and 10 minutes in the dash went off then the bike died. Basically battery flat. would jump off a jump pack and then die very shortly after being disconnected.

After pushing it home for two and a half miles (that was good fun) I've put it on charge and the meter is ready so start testing stuff in the morning. So my question is, are there regular failures with something on the charging circuit with these bikes to look for first (connector block corrosion or loom damage) I'm hoping its not the stator because I really don't want to pull that engine casing off again!!!

Cheers

RockingDad
 

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2008 YZF-R125 (180cc)
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have you got a multimeter? If so - check the voltage across the battery terminals with ignition off (shoudl be around 11.8-12.8 when charged), and when running (should be about 13.6~ volts)

If the voltage is not higher when running then your charging circuit has a problem.

If the voltage is low with the ignition off (e.g. 10v) and you've just charged the battery, then you may have a dead cell in your battery, though that would be unlikely on a new battery unless it was perhaps left on charge all the time since you got it or has been damaged some other way (idk what).

If your engine-running voltage is not higher as it should be, imho first thing to check would be just inside the left-hand side of the frame, about where the subframe starts and where the weld-seam is on the main frame spars. on the inside there's a thing bolted to the frame (rectifier i believe). That has a plug going into it from the underside (3 pins iirc). If that's not plugged in properly, or has corroded contacts, that would mean your charging circuit isn't happening and would give you that sort of running-flat along-the-way type issues as you describe.

If that doesn't work then I'd perhaps be looking at contacts in the plug which comes out of the stator etc. I'm not sure what the voltages are supposed to be on those plugs but it'll be in ther service manual.

Btw if you don't have a copy of the service manual... obtain one. There's pdf downloads to be had online (for gen1 anyway).

Voltmeter across the battery terminals should tell you what's going on tho :)

hope that helps.
 

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Discussion Starter · #3 ·
have you got a multimeter? If so - check the voltage across the battery terminals with ignition off (shoudl be around 11.8-12.8 when charged), and when running (should be about 13.6~ volts)

If the voltage is not higher when running then your charging circuit has a problem.

If the voltage is low with the ignition off (e.g. 10v) and you've just charged the battery, then you may have a dead cell in your battery, though that would be unlikely on a new battery unless it was perhaps left on charge all the time since you got it or has been damaged some other way (idk what).

If your engine-running voltage is not higher as it should be, imho first thing to check would be just inside the left-hand side of the frame, about where the subframe starts and where the weld-seam is on the main frame spars. on the inside there's a thing bolted to the frame (rectifier i believe). That has a plug going into it from the underside (3 pins iirc). If that's not plugged in properly, or has corroded contacts, that would mean your charging circuit isn't happening and would give you that sort of running-flat along-the-way type issues as you describe.

If that doesn't work then I'd perhaps be looking at contacts in the plug which comes out of the stator etc. I'm not sure what the voltages are supposed to be on those plugs but it'll be in ther service manual.

Btw if you don't have a copy of the service manual... obtain one. There's pdf downloads to be had online (for gen1 anyway).

Voltmeter across the battery terminals should tell you what's going on tho :)

hope that helps.
Thanks for your reply bud, your video on taking that side of the engine apart on YT helped previously with refitting the pulley key which I found in the oil pan when servicing from the previous owner. Stator turned up and I swapped it out and all good now, thankfully the regulator was ok because that looks like a total pain ITA to remove and replace. Just had the MOT today and failed on several things so yay some new projects, main one being adjusting the steering head bearing which has excessive wear or free play.... this bike is really fighting me to restore it to the road!

Cheers :)
 
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