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General Category >> Rubber Side Down! >> Intermittent Electrical Troubles
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Message started by Chipop73 on 07/03/14 at 05:27:40

Title: Intermittent Electrical Troubles
Post by Chipop73 on 07/03/14 at 05:27:40

Thought I had this problem whipped.
Excatly how do the Stator and/or Rectifyer work?
And how do I trouble shoot them?
I have fresh gas.
Fully charged battery.
Raptor petcock installed.
Bike is dead...no juice after sitting overnight.
Verified nothing left on or shorted out.
Perhaps I need Clymer and any other manuel.

Title: Re: Intermittent Electrical Troubles
Post by Serowbot on 07/03/14 at 06:42:51

Stator, is an alternator... makes AC current... test it with a meter...
Meter set to AC over 100v... check the 3 yellow wires under the seat that run to the regulator (Needs to be running, and rev to 3 to 5k rpm... (red probe to one yellow wire, black probe to engine or battery ground)... must check all 3 wires...
You should get 50 to 100v AC on each wire...all must make good voltage. increasing with revs...
Rectifier,... converts ACv to DCv, and regulates the DCv for charging... test at the battery... (again, engine running), meter set to DCv, you should see voltage of 13.4 to 14.8v.. but never lower or higher than that...as you rev the engine up and down...
With a strong battery,.. you may see volts drop when you rev... that's okay, as long as they stay above 13.4v....

You can jump start your bike with a car battery,..(NEVER have the car engine running)...
Don't do tests with the jumpers connected...

Have you double checked your fuses (with a meter)?... and check connections, including ground strap,(by the engine clutch arm)...

Best luck...

Title: Re: Intermittent Electrical Troubles
Post by BalingWire on 07/03/14 at 07:45:57

Electrical problems! I bounce back and forth between the flow of electrons and the flow of water as to which is worse.

I woke up this morning to a wife in the shower with no water, or rather, just a weak trickle. So I start my diagnostic process and discover the hinge pin on the float in the cattle waterer rusted completely and broke, and the water had been running all night and pumped the well completely dry. So I shut off the valve out to the barn/pasture, let the well fill up again for 15 minutes or so, and got her water to finish a shower. Then I fixed the cattle waterer.

All is well with the well again.

Good luck with ferreting out the electrical gremlins in the bike!

Title: Re: Intermittent Electrical Troubles
Post by WD on 07/03/14 at 10:06:04

Usual cause for all Savage electrical gremlins is the relay at the tank/seat joint mount. Under the frame, over the carburetor. Pop it loose, put it by your ear, give it a shake... ANY noise in that little box means you need a new one or you risk destroying the entire electrical system... Ask me how I know... 4 years and counting on my 98's full rewire courtesy of that little black box...

If the 03 relay goes bad, the bike is getting junked. Not going through that again with a zero collector value commuter vehicle. Ditto the timing chain, when it needs replaced, the bike is getting junked and I'll go back to hydraulically actuated lifters/pushrods. Overhead cam engines are not worth the maintenance headaches.

Title: Re: Intermittent Electrical Troubles
Post by justin_o_guy2 on 07/03/14 at 20:12:33

You CAN pull the key and leave the switch in a Kill My Battery position.

Title: Re: Intermittent Electrical Troubles
Post by Chipop73 on 07/04/14 at 07:57:43

Good news...and a little embarrassed.
Turned out my problem was corrosion on the neg battery terminal.
When I installed the new battery, 4 months ago, I lost one of the bolts.
The replacement bolt I chose from my junk can was too long. (I didn't realize that) When I tightened the terminal up, the bolt bottomed out...I thought it was good and tight....was not. Was making some contact, and gave no problems until 2 or so weeks ago.
Life lesson learend....always trouble shoot the basics first, before jumping to Stator, Rectifier/Regulator fears.
Thanks to you all who read, and helped.
Tim

Title: Re: Intermittent Electrical Troubles
Post by Dave on 07/04/14 at 15:21:19

Coo....A happy ending with no additional money spent. ;D