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General Category >> Rubber Side Down! >> charging system issues
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Message started by oldjeepguy on 07/09/13 at 09:33:04

Title: charging system issues
Post by oldjeepguy on 07/09/13 at 09:33:04

I bought a well neglected 1986 Savage - it's all corroded, forks pitted & leaky, bad oil leak from the head...you name it.
Anyway, I got it running, and it runs well. Yesterday, it started running rough and then stopped completely. Making a long story short, it was a poor connection where the fuse holder plugs into the wiring harness.
In trying to sort out the electrical system, I found the rectifier was very hot to the touch. The outside temp was 80 deg., so that would account for part of the heat. The rectifier used to be just a little warm after a 45 minute ride. Does anybody know a danger point in the temperature rise in the rectifier? I'm trying to understand symptoms of impending disasters. I have one of those Harbor Freight laser thermometers. I didn't use it to check the temp, but I will if I can discover the normal operating temp of the rectifier. Someone please help!

Things I've done so far:
Rebuilt forks
Sealed leaky plug in the head
Added little bullet LED turn signals
Pulled a big dent out of the gas tank & rattle can painted it
Made a 1/4 " thick brass spacer for the gas tank valve
Replaced throttle with a cheap aftermarket one
Replaced the right handlebar switch with a used Volusia part
Cleaned every electrical connection & greased with silicone grease

Title: Re: charging system issues
Post by verslagen1 on 07/09/13 at 10:10:13

check the connectors, make sure they are clean and tight.

a hot regulator may indicate overcharging the battery.

check you battery.

Title: Re: charging system issues
Post by oldjeepguy on 07/09/13 at 11:49:47

Yes, connectors are clean and tight. I checked them. The battery charge is normal. I monitor the battery. My concern is the temperature of the rectifier. What is the reason for the temperature rise? How much is too much?
Will a poor connection cause the temp to rise? I'm concerned because I know the high temp is a symptom of something, but I don't know what.

Title: Re: charging system issues
Post by Oldfeller on 07/09/13 at 12:20:09

The savage system operates by total loss of the excess current generated by the alternator It is normal for rectifier to get very warm in use if the battery is fully charged. There's nowhere else for the power to go. If the battery doesn't need it is wasted away as heat.

Title: Re: charging system issues
Post by oldjeepguy on 07/09/13 at 18:46:10

Sounds reasonable. Thanks. I wonder if it would be wise to put in some kind of thermal breaker to open the circuit instead of just generating waste heat? We would have a little more power and use a little less gas.

Title: Re: charging system issues
Post by Digger on 08/12/13 at 20:23:33

7D7E1F7D7E4B0 wrote:

Old,

Sounds like an interesting idea.....please let us know if you come up with anything!

TIA!