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Thread: Not charging (again) - 4th time in <3 years

  1. #46

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    Re: Not charging (again) - 4th time in <3 years

    With the help of Duck, I will be sorting this on the 7th of May.

    Will post an update.

    F

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  3. #47

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    Esteemed pals,

    I had a lovely morning with Pete.

    We cleaned everything off (v cheesed up wires and connectors).

    We soldered, we checked, we heatshrank, we checked again, we concluded it was fixed.

    Cold idle - 12.08v
    Cold revved up - 14.08v

    Sun out,leathers on, tyres checked, bike ready, voltmeter beneath seat, just in case.

    10 miles later, warm bike, stop, leave engine going, volt meter across battery.

    12.08v idle
    12.26v revved, even to 5 or 6krpm

    What on earth is happening?

    I can only conclude that (as Pete said may be the case) that something is breaking down when hot.

    I'll let it go cold and see what I get but the mystery remains unsolved....

    Sorry.

    Fred.

  4. #48

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    Are you checking at battery or output from reg? I found that when hot on mine there was a big difference ... something going high resistance in between. . Direct wired the reg to battery and all well with the world.
    No good deed goes unpunished!

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  6. #49

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    At the battery, not directly from reg rec.

    Bike is cooling (still hot to touch but not red hot) and I get:

    12.23v idle, 12.61v revved to 5k.

    The mystery continues,

    Fred.

  7. #50

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    Re: Not charging (again) - 4th time in <3 years

    Foeux
    I am guessing your still running a factory R/R correct? It could be the culprit that is failing under heated conditions.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

  8. #51

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    Re: Not charging (again) - 4th time in <3 years

    Quote Originally Posted by leighb View Post
    Direct wired the reg to battery and all well with the world.
    Did you direct wire the reg to battery? If not, then this is your next step. Don't forget to put 30A inline fuse/breaker on 12V wire. You must eliminate the factory loom from the whole charging circuit.

  9. #52
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    Re: Not charging (again) - 4th time in <3 years

    Quote Originally Posted by beestoys View Post
    Foeux
    I am guessing your still running a factory R/R correct? It could be the culprit that is failing under heated conditions.
    He has a later one from JAWS on there (as do I). This is said to incorporate 'mosfet technology' and I certainly noticed much improvement when I fitted mine (a long time ago now). I had the breaking down under heat issue with an older model (duff diode). Everything looked and tested fine in the garage, not happy here reading this, grumble grumble .........
    Full of Hot air? Intercool yourself............ you know it makes sense

  10. #53

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    Re: Not charging (again) - 4th time in <3 years

    Check at r-r, is most likely connection breaking down as fizzy suspects methinks?
    The answer is 42

  11. #54

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    Re: Not charging (again) - 4th time in <3 years

    Quote Originally Posted by TheDuck View Post
    He has a later one from JAWS on there (as do I). This is said to incorporate 'mosfet technology' and I certainly noticed much improvement when I fitted mine (a long time ago now). I had the breaking down under heat issue with an older model (duff diode). Everything looked and tested fine in the garage, not happy here reading this, grumble grumble .........
    Ah understand now Duck. Looking at the housing I suspected a factory unit. Ok so an option would be to fire the bike put a fan across the front then bump the idle up and hit the R/R with a heat gun while watching battery input voltage. If it's the R/R this may trigger your breakdown so that you can watch it happen. The other possibility is that the stator windings are breaking down due to heat as well. But that ones gonna be a bit harder to replicate. The other way if the R/R proves good and come to think of it'll work here too. Get a can of freeze spray and if the R/R does trigger then hit it with the cold spray and see if it recovers. You can do these same tricks with the stator by heating the cover mind you you'll have to be mindful of the painted cover.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

  12. #55

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    Re: Not charging (again) - 4th time in <3 years

    Typically, low voltage = bad wiring and /or bad stator

    High voltage = bad R/R

    You have low voltage

    1. Eliminate bad wiring, R/R to battery likely culprit.
    2. LOAD TEST stator after a run (to heat it up) using 240V 25W incandescent bulb (110V 60W better if available).
    3. Mount voltmeter on dash.

    As these bikes age, any stress points in the factory wiring start to break down, adding resistance and consequently lowering voltage

  13. #56

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    Re: Not charging (again) - 4th time in <3 years

    having a hangover day lol

  14. #57

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    Re: Not charging (again) - 4th time in <3 years

    Quote Originally Posted by Foeux View Post
    Fellow BBers. I followed the flow chart and have found the stator to be categorically goosed.

    Here you will see an image. Every combination of the 3 yellow wires returned 0v.

    The multimeter is fine and reads battery voltage well etc.

    New stator time again. As an aside the copper wire inside the yellow jacketing is all verdigris (green and crispy) like it is old or something.



    There is a wizard locally who does stator re-winding so may try him.

    Failing that it is new ring, new gasket and away we go again...

    The stator output is AC your meter is on DC, with the bike running you should see about 50vac+ with increased revs

  15. #58

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    Re: Not charging (again) - 4th time in <3 years

    Quote Originally Posted by Foeux View Post
    At the battery, not directly from reg rec.

    Bike is cooling (still hot to touch but not red hot) and I get:

    12.23v idle, 12.61v revved to 5k.



    The mystery continues,

    Fred.
    sorry if I missed it - sounds to me like a bad battery, what does the battery read with the engine off, to check this either throw in a battery or while running pull the earth off the battery with lights on full beam so you keep a load on the charging circuit and read the voltage on battery terminal -

    12.23v is just wrong no matter what - if the battery reads fine on its own then look at the starter solenoid connections - there is a plug in there that melts and causes all sorts of strange issues
    Last edited by GeoffXX; 05-13-2019 at 12:35 AM.

  16. #59

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    Re: Not charging (again) - 4th time in <3 years

    Quote Originally Posted by fizzy View Post
    80V ok. Now load test it.

    Repeat test using 120V 60W (or equal) incandescent bulb instead of the multimeter. Bulb should burn bright all 3 times when revved.

    If good then you either have bad wiring and/or a bad R/R. Honestly, I would upgrade to a genuine mosfet FH020AA or better yet a SH775/ SH847. Your present unit can be used as a paperweight. Check out this site Home. Sorry, don't know where to buy in UK. Anyway, follow advice from site and wire R/R directly to the battery.
    no need to load test it

    you have an interesting problem my friend

    In order to melt the RR output connector you would need to have a hefty load on there, so what's connected to the RR output - well everything, but most likely to go wrong is the Battery - a healthy fully charged battery should be about 12.6v, if you have a short it is most likely the battery, there are also problems around the starter solenoid and the main fuse located there - again burning and stuff like that - I had to rewire mine and fit an external fuse holder.

    Bad connectors melt - a bad battery loads the charging circuit up - something else shorting you would know about it, another thing worth doing is (with a fully charged battery) to turn on ignition and with engine off feel around the RR wires and starter solenoid area for heat

  17. #60
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    Re: Not charging (again) - 4th time in <3 years

    My gut reaction is that it is the RR that is giving problems (but yes the stator could be breaking down under heat).
    The battery is 'new' (OK that is no guarantee)
    We hard wired the stator to the reg rec (soldered). The remaining contacts in the plug block were clean.
    When we first checked the block it was 'nasty' with a sticky film all over and inside it, no idea what that was.
    Full of Hot air? Intercool yourself............ you know it makes sense


 
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