99 900S battery charging problem

[He Man]

New battery, doesnt get charged during normal operating conditions.

Got the fault finding guide from electrosport and just wanted to verify with you guys what im finding is correct.
http://www.electrosport.com/technical-resources/diagnosis-center/fault-finding-guide


1) Voltage across battery is 12v solid during idle
2) Voltage across battery is 12.3v during 2500rpm at ~5000rpm it is still only 12.5v
3) cleaned all contacts between voltage regulator, stator output and battery, both + and -. Did not apply dielectric grease.
4) all fuses are good to go.
5) the voltage reading between the + and - terminal on the regulator is only 6v at 5000rpm.
6) The 3 wires coming out of the left hand side (stator output?) are toasty hot. Not sure if it was due to its proximity to the motor or because there is high resistance somewhere.

According to the flow chart, my next step is to check the stator...makes sense so far? bike only has 16,000 miles on it.

[lawmaster891]

check the wiring from the stator to the regulator. On my 900 monster that wiring has 2 connectors that are known for building high resistance and burning up the wires. on mine i had the issue where it quit charging and those wires were sure enough burnt up.

[He Man]

so those 3 yellow wires that come out from the stator, there is a connector on the right side of the bike that connects to the regulator,

i tested them for resistance, not for voltage though ( i guess i could of tested the stator output for voltage to make sure the stator is working eh?)

so if there are 3 output wires, each one should carry how many volts? I can just take the lead and ground to frame cant i?

[Howie]

I seem to remember 78 volts at 3K RPM and the voltage should be fairly equal.  Probably anything over 60 is good, rule of thumb is 20-28volts/100 RPM.  The probes go from stator wire to stator wire with the regulator disconnected, polarity doesn't matter.  Do follow lawmaster891's advice, look for signs of overheating at the connector and crispy wires going back to the stator.  The stator is actually pretty robust, the wires and cheesy connector are not.  Oh!  You did check the 40 amp fuse, didn't you?

[He Man]

yup fuse is good and all the conectors look perfectly fine, no signs of being cooked or baking in heat.

i checked the output of the wires from the regulator and even at maximum rev i couldnt get the regulator output to be more than 6v.