Thanks Richard, Bill... great education I am getting a clearer picture all the time, will dig deeper into the loom at the engine and try to get a better earth there. Problem for me is the bus is up under the pod/canopy so I need to remove that and the loom at the engine is well hidden as well. Will just stop messing around on the surface and get into it.
Well I have no idea what is going on... located the brown earth wire on the engine mount and checked and cleaned that... all appears fine. Checked voltage at the regulator and it has specifications on the side for voltage but the wiring is nothing like I have been able find a schematic for... voltages are black and red at about 13.5 and a are fine. It has two blue wires which read at about 7v...
yellows wires are also showing 13.5 volts... Richard where did you get 30v from?
Anyway grey wires check was a no go as I could not add RPM and check while alone... new tach ordered and if that fails I will use a Tiny Tach.
The 30v is the input voltage from the lighting coil to the regulator. It is alternating current and will probably be anywhere from 30Vac at around 3000rpm up to 80Vac at full speed. The rectifier converts the ac to dc and the regulator keeps the dc volts steady at around 13.5vdc to 14.5vdc.
It sounds more and more like your lighting coil and regulator/rectifier are OK. I don't know what year Rotax moved the tach wire resistor outside the mag housing. Roger can probably answer that one. It still sounds like the problem is either a bad tach, the grey wire/resistor, or the tach ground.
The 30Vac was measured across the yellow wires. They were disconnected from the regulator at the time, from memory. As long as there's AC voltage generated by the mag windings, and the reg-rectifier is good, your battery will charge. This has nothing to do with the tach, however...
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