Step By Step - How to Fix Persistent Charging Problems
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Thread: Step By Step - How to Fix Persistent Charging Problems

  1. #1

    Member #
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    Step By Step - How to Fix Persistent Charging Problems

    Dear BB users. Like me, many of you have charging woes. This has fixed them. I got tot he point of cutting my losses and selling the thing and this has encouraged me not to do that. Huge thanks to Pete for helping...

    Parts:

    Reg Rec and with wiring it (Jack’s)
    Stator (West Country Windings)
    Stator cover gasket
    Reg Rec Bracket (Baking tray and 10mm Alu stock)

















    Kit:
    Allen keys (4mm, 5mm, 6mm)
    ¼” Ratchet
    ¼” Extension
    ¼” drive Sockets (8mm, 10mm)
    ¼” Torque Wrench (12ft/lb)
    Crimper
    Scalpel
    Drill
    Tinsnips
    Wire cutters
    Needlenose Pliers
    Drill
    Drill bits
    Centre punch
    Hammer
    M6 Bolts
    M6 washers x4
    M6 Nylock Nuts x2
    Heatshrink of various sizes
    Heat Gun
    Zip Ties
    Silicone Sealant
    Loctite
    Washing up liquid
    Cereal Box
    PH2 Screwdriver
    Wooden Block

    Method:
    1) Greet Pete, clear area for deck chair, drink coffee made for us.




    2) Remove side fairing (5mm, 6mm, poppers). The trick to this is to undo all of the bolts and poppers but the top middle one, this holds it steady and stops it bending, breaking or hitting the floor. Keep bolts in a pile or a separate container.







    3) Remove tail fairing (5mm, 6mm). When all bolts are out, remove handle first, then gently pull tail up and back, pulling the sides apart gently for clearance. Store out of the way. Keep bolts in a pile or a separate container.



    4) On a piece of cardboard cut from a cereal box, recreate the pattern of the stator bolts, marking each location with a cross cut with the scalpel.
    5) Begin to undo the stator cover bolts (8mm ¼” drive socket, ¼” ratchet, ¼” extension). Crack them all off first then go about removing them. Place each bolt into the corresponding hole on the cardboard. Mark the top with a grubby thumb.
    6) Firmly grab the stator cover, rock it a bit and it will come away.
    7) Snip the three yellow stator wires with the wirecutters.
    8) Sit on deck chair and undo 4x 5mm allen bolts to remove redundant up stator ring.











    9) With scalpel, gently remove any silicone residue from U-shaped trough into which the 2x rubber grommets for the stator wires slot into.
    10) Remove old grommets from old wires by placing in hot water and pulling each wire out with pliers.





    11) If not brittle, patiently rethread grommets onto new stator wires using washing up liquid as lube. Be sure the pattern matches on both grommets, no twists between the two.





    12) Using 8mm socket, remove the old reg rec. Retain the two bolts, discard the reg rec.





    13) Use a piece of paper and a grubby thumb to make a ‘rubbing’ (think primary school, crayons and tree bark) of the bracket already there to take the stator. The new one won’t fit and needs a bracket fabricating.



    14) From a piece of baking tray, using tin snips, cut a square big enough to cover the existing bracket and the size of the new RR. Refine any sharp edges with the bench grinder.



    15) Using your new grubby thumb rubbing, centre punch, hammer and drill the 2x 6.5mm holes That will allow the piece of baking tray to attach to the old bracket.



    16) Hold the new RR on with zipties and check the tail fairing clears it.





    17) Mark the baking tray by scratching it with the punch as you have the RR in place.
    18) Remove baking tray, mark, punch and drill 2x 6.5mm holes. This marks the location of your RR and the 10mm block of alu you will make to keep it proud of the original boltheads.
    19) Place the new stator ring into the cover and secure the 4 bolts with a bit of Loctite and a 5mm allen key.
    20) With a bit of black silicone as glue, push the little grommets into the u-shaped trough.
    21) With little dabs of silicone, secure the new gasket to the cover, the little dowels also help this to seal.
    22) You get one shot at this and is all clamps together magnetically so get it right and mind your fingers.
    23) Remove the bolts from your cereal box template and get them finger tight.
    24) Torque them to 12nm with the 8mm socket and your torque wrench. Pete advises to work in a diagonal pattern and I make brackets from baking trays. Do it Pete’s way.
    25) Undo 2x bolts holding tank and lift it up. Prop it with a piece of wood to make cable routing easier.



    26) Route the cables up to a place they can reasonably make friends with the new RR making sure you sleeve them in black rubber.
    27) Get the pluggy bit of the kit with 3 yellow wires protruding and slip a bit of heat shrink over it (big enough to cover the connectors you are about to crimp).
    28) Doing one, then the next then the last, shove the stripped ends into the connector and crimp with crimping pliers.



    29) Slide the heat shrink over and begin using a lighter to shrink it. Resolve to use Pete’s Danger-Lux 5000 hairdryer later.



    30) Go to Pete’s house to fabricate a 10mm thick bracket from aluminium which puts my baking tray to shame.
    31) Marvel as Pete overtakes a slow car in his slow van.
    32) Make the bracket and return home (thanks Pete).







    33) Use the hairdryer to heatshrink the connectors.





    34) Using 8mm socket, attach the baking tray bracket to the old RR mounting.
    35) Slip bolts (M6, 30mm long, washers and nylocks) through RR and through new spacer.



    36) Attach the RR spacer combo to the bracket and tighten.
    37) Clip plugs into RR and route the cables where you can, attaching the red and black wires to the battery terminals.



    38) Secure the wires wherever you can to make them look neat and to allow the seat to go on.
    39) Check it works.



    40) Fit the fairings (reverse of removal).



    41) Rejoice.

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  3. #2

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Great write up, just awaiting my RR to clear through customs :-)
    Roses are red, violets are blue, I'm schizophrenic, and so am I.

  4. #3

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Great write up Fred. The baking tray saga? Heard about it . Nice to see Duck on the mill, unusual . There's a set of those rubber sealing washers for you at Ducks along with an angled one . That a Bahco 1/4 drive ratchet i spy? Got three of those sets. Bike, garage and van. Good pieces of kit.
    Your troubles are now over.
    carpe diem

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  6. #4

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    Re: Step By Step - How to Fix Persistent Charging Problems

    If you find the grommets are hard mix Up a solution of 1 part wintergreen oil 3 parts rubbing alcohol. Soak the parts for about 1 to 2 hours and the rubber will restore back to flexibility. If they don't then soak them longer until they do.
    johnnyquick likes this.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

  7. #5
    Supercharged Mod
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    Re: Step By Step - How to Fix Persistent Charging Problems

    Quote Originally Posted by Gadgey View Post
    Great write up, just awaiting my RR to clear through customs :-)
    Mine arrived yesterday having cleared customs. Daily Bird is currently charging perfectly but with a big trip across Europe coming up and my service records showing I have covered 23K miles since I last had problems I'm getting twitchy! I'm going to pull the charging system and replace it, that should save me from having to carry a spare stator, reg rec, gasket and gas soldering iron on my travels!
    Gadgey likes this.
    Full of Hot air? Intercool yourself............ you know it makes sense

  8. #6

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    Re: Step By Step - How to Fix Persistent Charging Problems

    I've been averaging 22,000 thousand out of the ones I've gotten from Rick's. So your probably about right Duck.
    TheDuck and Gadgey like this.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

  9. #7
    Supercharged Mod
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    Re: Step By Step - How to Fix Persistent Charging Problems

    Quote Originally Posted by beestoys View Post
    I've been averaging 22,000 thousand out of the ones I've gotten from Rick's. So your probably about right Duck.
    Now the quandary starts ......

    Pulled the stator to start a preemptive stator/reg/rec change expecting to see a blackened stator after 23K miles.
    What I have found is what looks like a stator that has covered less than 100 miles! The only discoloration is on the 3 yellows that are brown with the engine oil.
    Hmmmm, to change the stator to a new one that could fail at any time or leave the stator alone since all the figures are perfect?

    IMG_2121.JPG
    Full of Hot air? Intercool yourself............ you know it makes sense

  10. #8

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Leave well alone Pete, quietly put it back and tiptoe out.....
    adeyren and TheDuck like this.

  11. #9

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Quote Originally Posted by TheDuck View Post
    Now the quandary starts ......

    Pulled the stator to start a preemptive stator/reg/rec change expecting to see a blackened stator after 23K miles.
    What I have found is what looks like a stator that has covered less than 100 miles! The only discoloration is on the 3 yellows that are brown with the engine oil.
    Hmmmm, to change the stator to a new one that could fail at any time or leave the stator alone since all the figures are perfect?

    IMG_2121.JPG
    Bit of a dilemma there Duck,
    It just looks to good to swapout, Coin toss?
    Roses are red, violets are blue, I'm schizophrenic, and so am I.

  12. #10

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Quote Originally Posted by Rocketeer View Post
    Leave well alone Pete, quietly put it back and tiptoe out.....
    ^+!. There again, take the spares as usual. You never know.
    carpe diem

  13. #11

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Ok
    In this case carry the spare if it ain't broke don't fix it. Especially considering how that one looks. You sure your looking at the right odometer or have the right numbers for your change out from before.
    Route 191 formerly Route 666 Some say that this section of the
    road has 1100 curves in 95 miles.

  14. #12
    Supercharged Mod
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    Re: Step By Step - How to Fix Persistent Charging Problems

    Yesterday I decided that the stator stays (and the spare comes with me) glad others have taken the same view, it was a real quandary when I pulled the cover. Yes the mileage is correct which was why I was feeling really guilty when Foeux was having so many issues, I helped fix his bike 3 times (or was it 4!) and all the time mine was working fine.

    What I think I will do today is replace the reg/rec. I have one of Jack's here (FH020AA) and again whilst the existing one is working fine (JAWS 'with Mosfet technology') the current one wires to the loom (as standard) removing this weakness here has to be sensible with a 20 year old loom.
    Full of Hot air? Intercool yourself............ you know it makes sense

  15. #13

    Member #
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    I do indeed use Bahco and it's ace stuff. FREDPROOF.

    Pete, I hope I am not just cursed but yours looks perfect....

  16. #14
    Supercharged Mod
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    Re: Step By Step - How to Fix Persistent Charging Problems

    Quote Originally Posted by Foeux View Post
    …. Pete, I hope I am not just cursed ....
    Nah no such thing, I had a spell where Daily Bird was eating stators and reg/recs, I even had one go down hours before I was due to be on a ferry to France. I'm a great believer in the 'sh.t happens' theory.
    Full of Hot air? Intercool yourself............ you know it makes sense

  17. #15

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    Re: Step By Step - How to Fix Persistent Charging Problems

    Since I'm a brand new BB owner and found practically a brand new BB: Is this problem occurring on every BB or only on 1 of every 10 or maybe those that ride in rain continually? BTW, all my bikes after every commute goes on Smart Chargers until the next ride. I typically get eight years out of my batteries.
    Last edited by [email protected]; 06-18-2019 at 8:20 PM.
    '11 Concourse, '08 B-King, '02 Super Blackbird


 
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