new rectifier, relatively new battery, not charging

[Privateer]

I seem to have a dead/dying rectifier.  Unless I did something wrong, at idle I was only seeing 6v output from it.  The stator input at idle was in the 18-20v range.

Is this what I need?
http://www.ca-cycleworks.com/products/electrical/electrosport-regulator-esr532

[Speeddog]

That RR will work for your bike.

Here's a good testing procedure to identify the problem:
http://www.electrosport.com/technical-resources/library/diagnosis/fault-finding-guide.php

[Privateer]

That RR will work for your bike.

Here's a good testing procedure to identify the problem:
http://www.electrosport.com/technical-resources/library/diagnosis/fault-finding-guide.php

thanks for the link.  I did just a quick 'check battery, check stator, check rr' when I got home tonight, but going to follow that full diagnostic tomorrow to ensure the cause.

[Privateer]

That RR will work for your bike.

Here's a good testing procedure to identify the problem:
http://www.electrosport.com/technical-resources/library/diagnosis/fault-finding-guide.php

so I'm following the steps and I'm confused.

On the first page, I set to DC, rev the engine to 2500 and I got less than 13.5v
I have 2 wire colors (2 red, 2 green) coming from the RR.  The next steps says "connect red to the red output wire, black to the battery" and I got 1.9V.  It says "less than .2v" or "more than .2v"  which 1.9v seems way over the .2 threshold.

in the meantime, while idling, I noticed the RR got really hot which concerns me.


argh

[suzyj]

The check you're doing is to ensure that your wiring is okay.  If it's good, the voltage along any given wire (red at the RR to battery +, for example) should be really low.

In your example, the wire is high resistance, so the voltage across the wire is very high.  This is probably due to a burned out connector.

The way RR's on most bike work is that the stator produces power, which the RR then regulates down to the battery voltage and charges the battery.  Once the battery is full (or if the battery isn't accepting the power because of a wiring fault, like you have) the RR then dissipates the excess power from the stator as heat.

Your RR may not be stuffed at this point, but if you continue to use the bike like this, it's only a matter of time before it is, and it's likely to catch fire.

[corey]

recently did some stator and rectifier work on my girlfriends gixxer... my plan of attack was simple...
replace the entire charging system...
lol

(seriously though, that's what we did... new stator, R/R, battery... bike runs like new)

[H-2 CHARLIE]

 looks like it is the esay fix and change out the one part for a C note  .. Use silacone grease for the plug .

[Howie]

If you have output from all three stator wires, the connection to the regulator is good, all other connections (including grounds) are good and you do not have 13.5-14.5 volts at the red wire to the battery you need a regulator.  Oh, and hot is normal.  Your car regulator controls charging by inceasing or decreasing field strength.  Your Duc regulator does this by turning excess generated electricity into heat.

[Privateer]

well replaced the R/R, jumped it off my car, idles for a few minutes then dies.  Pretty much the same as it did the day it died on the street.

[suzyj]

well replaced the R/R, jumped it off my car, idles for a few minutes then dies.  Pretty much the same as it did the day it died on the street.

Good to hear your RR is good then!

Now go and actually troubleshoot the problem before spending piles more money.

[Privateer]

the electro sport guide says to check the connectors between the RR and the battery... not even sure where they are let alone how to check them.

I wish i wasn't broke at the moment...

[Privateer]

I followed the output wires based on the "You have a bad positive connection" and didn't see any obvious connectors, everything seems to be hidden in the wire harness.

OK, so another ignorant question.  following the trouble shooting guide, it says to check the V while touching the negative battery terminal and the positive output wire from the RR.  it also says to 'keep the RR connected' while doing that.  

do they mean keep it connected to the input from the stator and unplug the output connector?


Thanks.

[drunkfatguy]

I followed the output wires based on the "You have a bad positive connection" and didn't see any obvious connectors, everything seems to be hidden in the wire harness.

OK, so another ignorant question.  following the trouble shooting guide, it says to check the V while touching the negative battery terminal and the positive output wire from the RR.  it also says to 'keep the RR connected' while doing that.  

do they mean keep it connected to the input from the stator and unplug the output connector?


Thanks.

The guide says nothing about removing/unplugging anything, I would think that they mean backprobe the connection at the RR connector for the positive output wire that goes back to the Positive battery connection circuit so a voltage drop measurement can be done. Think of it as a plugged strainer in a water pipe and you are reading a differential pressure gauge(a gauge that takes the difference between the pressure of the inlet to the strainer and the outlet).

[Privateer]

The guide says nothing about removing/unplugging anything, I would think that they mean backprobe the connection at the RR connector for the positive output wire that goes back to the Positive battery connection circuit so a voltage drop measurement can be done. Think of it as a plugged strainer in a water pipe and you are reading a differential pressure gauge(a gauge that takes the difference between the pressure of the inlet to the strainer and the outlet).

thanks.  i'm pretty new with troubleshooting electrical... wasn't sure how I get the probe inside the connector.  Figure that out tomorrow I suppose.

[zooom]

thanks.  i'm pretty new with troubleshooting electrical... wasn't sure how I get the probe inside the connector.  Figure that out tomorrow I suppose.

use the pointed needle end probe connectors and pierce the insulation of the wire into the copper....do your measurments on both sides of the connectors...