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Message started by popcykle on 08/19/11 at 16:38:02

Title: charging issues??
Post by popcykle on 08/19/11 at 16:38:02

I have read thru many posts but have not found the info I am looking for...

New regulator / rectifier installed, only getting 12.5 v when revving, and the rectifier is getting HOT!!

Tested stator, over 100v across the contacts when revving engine. Tested with engine off, small resistance across all 3 contacts, nothing to ground...

Am I missing something???? :-/

1999 model

Thanks in advance

Title: Re: charging issues??
Post by Markusublime on 08/19/11 at 21:40:15

Are you getting 13-14v at either the red/blk and org/blk wires at the regulator? Make sure you have a good ground through the blk/wht wire too.if you know how to do voltage drop testing use that for more accurate results.it sounds like the regulator sees a demand but isn't getting the voltage to the battery like there's a broken wire somewhere.you may have also gotten a faulty regulator that doesn't provide the voltage through the charge wire though it may see a demand for it through the sense wire.

Title: Re: charging issues??
Post by popcykle on 08/20/11 at 13:17:08

I have tested and am getting 12 v at red black and 11 v at orange black

Ground wire appears and tested ok

started bike, plugged in reg/rec and noticed rpm drop

tested output of reg/rec and got .9 v....

question: what would plugging a 6 wire reg/rec into this bike do? Some reg/rec are 5 wire, some are 6 . wondering if a 6 wire was plugged into it would it blow something somewhere, as this bike is a 5 wire.

Title: Re: charging issues??
Post by Markusublime on 08/20/11 at 17:33:38

Looking at the wiring diagrams on clymer's I don't see a 5 wire regulator showing from 86-06,you should have 3 wires from the stator,a red/blk,a blk/wht,and a org/blk which one is missing on yours?does in look factory or like someone may have removed the wire?

Title: Re: charging issues??
Post by popcykle on 08/21/11 at 04:35:42

99 and orange wire IS there, but the reg / rec only had 5 wires (no orange one)

when issue started pulled a 6 wire from a donor bike, installed and it worked (briefly, tested and got 14.4) but a week later and the batt was dead again.

Tested once more, only 12v so spoke with guy at shop, mentioned 5 wire vs 6 wire and was told a 6 wire would not work, so ordered me up a 5 wire reg/rec (no orange lead)

Title: Re: charging issues??
Post by Routy on 08/21/11 at 06:33:33

Speaking only from a few yrs experience w/ Kohler engine repair, I'd first be checking the stator,....first for coil continuity, then for no shorts to ground,....then wiring to regulator,......continuity and shorts, then the regulator itself.
But what do I know about motorcycles ! ::)

Title: Re: charging issues??
Post by popcykle on 08/21/11 at 20:05:00

Routy, I have tested it as per the Clymer manual and it is working as per specs (100+ v across all the leads)

Have tested with bike not running and am getting small resistance on the leads, nothing to ground...

have tested ground and it appears to be good...

reg / rec is a new part...

Looked over the wiring diagram, there is no relay that may be faulty...

What am I missing???

Title: Re: charging issues??
Post by popcykle on 08/22/11 at 08:00:29

Ok so started from square 1 and systematically went thru everything and believe I have found the issue, tho still have a question.

P/O had installed extra lights on the side of the headlight. Once I disconnected those, I then was getting proper voltage to the battery (14.4)... connect them and the voltage drops to 12.4 ish

Now to the question... I understand that the r/r converts unneeded power over to heat, but holy crap that sucker gets WAY hot, almost too hot to handle.... is this normal operation?

Title: Re: charging issues??
Post by popcykle on 08/22/11 at 09:06:34

continuing the troubleshooting I had a thought and grabbed the 6 wire r/r I had, disabled the orange / black and plugged it in (without the extra lights connected)

solid voltage 14v but when connecting the extra light back up, still drops to 12.4 or so

leave machine running (no extra lights) for a few min, this r/r just gets warm (methinks the heatsink on the aftermarket is insufficient)

have it all buttoned up now, with modded 6 wire r/r running and extra lights removed completely and getting solid voltage range when running... wonder if the shop will at least give me credit for the aftermarket new r/r that I don't need... prob not....

Title: Re: charging issues??
Post by Markusublime on 08/22/11 at 17:57:48

Glad to hear you got it all fixed up.what kind of lights are you talking about?they must be pulling some serious power.

Title: Re: charging issues??
Post by popcykle on 08/23/11 at 04:14:34

small halogen side units that are meant to be connected to the sides of the main headlight, small sealed beam.

the only thing I can see on them is raised in the glass YUNGLI

Anyway scoot is running fine now (is g/f's bike) we went out to dinner last nite and I escorted her to work this morning (she is still learning, I feel better if she is not riding alone just yet...)