Charging issues narrowed down (with pic)

Jarvicious · October 08, 2012, 10:59:28 AM

Long story short, I've been browsing around here on various charging/reg/rec threads to try and figure out why the old girl won't hold a charge. Fully charged on the battery tender, I get ~12v at the battery, no matter what. When I pulled the connections to my regulator/rectifier I found that the 6 pin connector came off just fine, but I had issues removing the 3 cable connector that goes to the stator. A lot of PB Blaster, pinched fingers (via channel locks) and cursing later, I got her off to find this:

I sent the regulator off to Ricks Motorsport electrics (who have fantastic turnaround and customer service, by the way) to have them test it, and apparently it's just fine. My cell phone camera doesn't really pick up the details, but there's even a bit of melted plastic around the spade terminal from where I assume the substantial voltage coming out of the stator was simply resisted by all the bullshit and corrosion caked on to the connector. They put a new terminal on the rec and are sending a new set of terminals for me to crimp on to the end of the stator cable so hopefully I haven't fried anything internally, but I figured I would give folks something to check out next time you're doing a valve check, oil change, or just giving the bike a good once over. I usually try to check brakes, plug wires, coils, etc for damage or other issues while I'm tinkering around, so keep a weather eye on this.

Oh, and Ricks charged me $30 for testing, terminal replacement, and the new terminal for the stator end. I know my way around a volt meter and I'm sure I could have diagnosed the R/R myself, but sometimes it's worth a little peace of mind.

ducpainter · October 08, 2012, 11:17:16 AM

That connector has been problematic forever.

You can replace it with a better one, or simply solder the wires together.

Jarvicious · October 08, 2012, 12:33:50 PM

When the new kit gets here I'm planning on weather proofing the whole thing a bit better as well as using a bit of dielectric grease on the terminals. That is if my stator isn't fried... $:-\$

motoxmann · October 09, 2012, 04:24:25 PM

I've had intermittent wiring problems on my duc randomly too ('00 M750), and actually found that every issue I've stumbled upon was fixed by simply crimping the female spade terminals in related connectors down a bit tighter so they made a definite solid connection with the male terminals. which makes perfect sense because issues I've had were more apparent at specific rpms (specific vibration frequencies), and being old the terminals simply opened up a bit and were making inconsistent connections.

Nottsbiker · October 10, 2012, 04:40:13 AM

Aprilia's often do this as well, and its helped by soldering the wire to the connector for a better fit.

My Tuono did it so I replaced the ill-fated brown plug with a higher rated one and its been all good ever since

BK_856er · October 10, 2012, 10:00:37 AM

Exact same thing happened to my '07 and my stator was fine afterwards. I know you just spent some bucks getting a new terminal put on there, but ducpainter gives good advice. Best to solder the wiring or uprate the connector for longterm reliability. Nothing more frustrating than a no-start in the middle of no-where!

BK

Howie · October 10, 2012, 06:13:12 PM

I prefer not soldering the wires since future diagnostics are difficult. The connector is indeed cheesy, but mine still is fine after 11 years and 63K miles. The trick is keep it clean and tight, packed with dielectric grease. If i ever need to replace it would I get a beefier connector? You bet.

Jarvicious · October 12, 2012, 01:59:44 PM

Ricks is sending a new connector with the R/R so hopefully it will be decent. Definitely lots of dielectric grease, and I'm hoping I have some shrink wrap that will fit over the back of the connector where the wires enter. It seems strange that manufacturers who know that the electrial connectors are going to be out in the rain would come up with a different connector design.

BK_856er · October 12, 2012, 03:48:26 PM

My '07 was never used in the rain (calif.) and was stored in a garage between weekend canyon rides. Never even hosed it down for the rare wash. Still only took a few years for that OE connection to fry itself. Just takes a tiny bit of connector resistance at those large currents to generate a ton of heat. The metri-pack 280 connectors look like a good option:

http://www.easternbeaver.com/Main/Elec__Products/Connectors/R_R_Connectors/r_r_connectors.html

BK

Howie · October 12, 2012, 05:23:15 PM

Link saved!

Jarvicious · October 13, 2012, 07:21:35 AM

Quote from: BK_856er on October 12, 2012, 03:48:26 PM
My '07 was never used in the rain (calif.) and was stored in a garage between weekend canyon rides. Never even hosed it down for the rare wash. Still only took a few years for that OE connection to fry itself. Just takes a tiny bit of connector resistance at those large currents to generate a ton of heat. The metri-pack 280 connectors look like a good option:

http://www.easternbeaver.com/Main/Elec__Products/Connectors/R_R_Connectors/r_r_connectors.html

BK

Those look a lot like the ones we have on our headlight connectors. You know, the weather resistant ones... I'd be willing to bet if they traded the two at the factory it would have saved some people a lot of grief.

BK_856er · October 13, 2012, 12:48:23 PM

Quote from: Jarvicious on October 13, 2012, 07:21:35 AM
Those look a lot like the ones we have on our headlight connectors. You know, the weather resistant ones... I'd be willing to bet if they traded the two at the factory it would have saved some people a lot of grief.

Agreed. The weather sealing is nice, but the metri-pack electrical connectors themselves are also far more robust than the standard spade connector. Instead of relying on a primitive interference fit, there is a "spring" feature to help ensure good mating and electrical contact. The OE connector meltdown is very annoying!

BK

Jarvicious · October 15, 2012, 03:51:09 PM

Updates! It's not the R/R

.

Mine came via brown truck today (by a friendly courier who hung out in the garage with me for a minute or two talking brutal crashes) with a shiny new connector attached as well as the spare to crimp onto the bike. I took great care in crimping each terminal carefully and made doubly sure that the wires coming out of the stator matched in both terminals. I wasn't sure if any weird voltage or electrical frying issues could occur, but I didn't want to take any chances. I also hope they attached the connector to the regulator properly.

After I got everything back together (with a good helping of dielectric grease) I broke out the old meter and turned it on. I got around 12.4 with the bike off, around 12.3 with just the ignition on, and 12.xx (don't remember. I think I may have passed out momentarily in a blind rage) when the motor was at 5k rpm+.

I did however get the 999 masters fitted and bled so I just had to take her around the block a few times despite the charging issue. When I got back I checked

- 40amp fues (fine)
- 5 amp charging fuse (fine)
- the regulator was good and warm, as it should be

Until I have time to go out and meter the individual stator wires, should I assume that my stator is toast?

ducpainter · October 15, 2012, 03:52:51 PM

Or the wiring.

I forget...did you inspect the stator plug?

He Man · October 15, 2012, 08:07:58 PM

Quote from: ducpainter on October 15, 2012, 03:52:51 PM
Or the wiring.

I forget...did you inspect the stator plug?

+1 check each plug on the stator end and make sure you are on AC.

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Charging issues narrowed down (with pic)