The ballast resistors add load to balance the lighting/charging system . The 4 pin regulators do two things . One thing is rectify the ac to dc and regulate for the charging system 12-14.5vdc . The other is to regulate the ac voltage for your lighting . Here is where the problem is , the regulator can only clamp/load down the voltage so much . So say stock your ac system is 60watts , lets say for example the ac power output on the lighting ckt on the stator is 70watts at 14vac . That is powering your headlights dash lights, 35w headlight and 5 5w little bulbs in the dash . In the stated situation the regulator takes care of the extra 10w ac and can keep the ac voltage regulated at or below 14vac . Now things are balanced everything is working well together , good ac lights and good charging voltage. Then you decide for example you want orange dash lights and get leds , so the 5 5w bulbs you change in the dash ( an led uses about 15% power what a bulb uses) 15% of 25w=3.7w lets call it 4watts from the 25 leaves 21 extra watts for the regulator to dump , when it dumps too much it gets hot , then its a matter of time till it burns itself out . But in the mean time the ac voltage goes up above 14vac ad pops your headlight .
Thanks for that John. I only owned one scoot that had a ballast resistor. Same scoot had a lot of wiring issues when I got it. I replaced the harness with one that did not use a ballast resistor. Never had a problem with the electrical system after that so it seemed like the super hot ballast resistor was little more than a burn hazard to me.
The ballast resistor is used to provide a load for the stator when the lights are not on. With a load in place the stator voltage won't go terribly high but the voltage is not limited or regulated. Many scoot wiring diagrams I have seen just run the lights all the time. The problem with that is when a light burns out. Some regulators seem to have voltage regulation for the lighting circuit. Some require the ballast resistor to dissipate some of the heat, others will work without the ballast. One never knows until the magic smoke comes out.
Ballast resistors are rated by wattage and stamped with resistance. here is what I use in the shop, I have used up to 6 to get the system balanced.
the mounting on some are for ground,some come two wire, bottom line you need to have a certain amount of load to keep things in range. Most change to regular bulbs to led and things get all out of range, pop bulbs burn wires over charging burnt out regulators. It can get a little involved to get things back in balance.
Last Edit: Nov 16, 2017 20:02:18 GMT -5 by 90GTVert
Brent Smoking section, please.
Senna1Rossi: Ah, gotcha! Thanks, Fox. Does everyone see the Shoutbox, or just the people who you choose?
Feb 16, 2016 12:39:35 GMT -5
Fox: Anyone who is logged in can see it but it's down at the bottom so most have either chosen to ignore it or haven't discovered it yet.
Feb 16, 2016 18:42:39 GMT -5
Deleted: Wow, I just found this. I feel smart now, ha ha.
Feb 27, 2016 19:24:24 GMT -5
Silar: Ahh.. New feature for a new riding season! YAY!
Mar 16, 2016 17:12:34 GMT -5
Silar: Apparently this still is not being used much. hmm..
Mar 17, 2016 13:55:04 GMT -5
180°off: Anyone want to buy a Yamaha 2t that needs a complete rebuild?
Mar 27, 2016 16:00:19 GMT -5
larryhobman: What is the leanest jet size you would try on a 47mm setup, 60cc stock head with a A9 cam
Apr 2, 2016 20:17:30 GMT -5
Senna1Rossi: Thanks renagade281!
May 23, 2016 14:59:12 GMT -5
Fox: I don't really know how to say this but straight. I am Dave's Girlfriend Kellilee and bluntly and VERY SADLY he passed away early Tuesday morning. I know he would want ya all to know this. Thank You Brent for befriending my love he was very happy on here!
Jun 18, 2016 16:26:04 GMT -5
Fox: www.gofundme.com/29mgf6b8 I hope it is ok to pass on his gofundme page link. If not you will un-post it I'm sure. Thanks again all!!
Jun 18, 2016 16:31:18 GMT -5