Stopped charging again

*ratchetman* · 06-07-2007, 11:23 PM

That's the second farthest I've ever pushed a bike. It ran 2 weeks to the day that I got it back from the last breakdown. Last time it stopped charging as well, the stator was bad. I'll charge the battery all night at 2 amps and tomorrow if I make it to work I'll test it to see if it's the stator again or the regulator/rectifier. I've had the bike 5 weeks and been on the side of the road three times.

Renegade929 · 06-07-2007, 11:46 PM

did you replace the stator once already ? If so, it could have been your reg,rect the whole time .Check your stator right at the wires coming out of your engine case.Also make sure your battery is not junk to begin with.Take a multi meter and check how many volts are being put out at the battery with the bike revving at 5k rpm ,should be 14-15....i already went through this with my 929,stator was toasted,replaced it and it's been working great so far (knock on wood)......Denniskirk has the best deals on good quality stators, with 1 year warranty's to boot !

*ratchetman* · 06-08-2007, 12:24 AM

Last time the stator was shorted to ground and had broken wires. I tested the battery last time and it seems to take a charge ok. It resistance tested to 235 cca. The stator I bought from RM stator also has a one year warranty their price for the r/r is $109 us.

Sime · 06-08-2007, 11:30 AM

Check the R/R plug. Two of the 3 of my stator wires rusted at the plug, thus not allowing the bike to receive a charge.

Pull the plug off the rectifier to check.

*ratchetman* · 06-08-2007, 2:55 PM

Plugs are ok. Although the manual doesn't give a spec for stator voltage, mine's only putting out 1-1.5 volts a/c. Whether it's connected or not. Even with the r/r output plug disconnected from the bike. The resistance on the stator is within spec and there are no shorts to ground.

*ratchetman* · 06-08-2007, 8:15 PM

I have removed the stator, it smells bad and the engine oil is black. I have a 2/3 rewound stator at home that I will finish and install to see if I can find out why it burned up. Does anyone know how many amps the bike should draw from the charging system while running?

*ratchetman* · 06-10-2007, 2:20 AM

It's working for now. I finished rewinding the original stator and installed it. The bike is drawing about 15 amps. I figure this is normal. I found the problem with my new stator. Where the windings are soldered to the wires about 3 inches of the wires were burnt to a crisp. I can only presume that whoever made the connections screwed up and failed to insulate properly. If it had burned up due to over loading I think the wire would have burned all along it's length

Renegade929 · 06-10-2007, 4:51 AM

so you fixed it and checked the output at the battery afterwards ? If your getting 14-15 on the meter at 5k ,your doing good ,and your problem should be solved .did you epoxy the windings ?

*ratchetman* · 06-10-2007, 3:22 PM

Quote:

Originally Posted by Renegade929

so you fixed it and checked the output at the battery afterwards ? If your getting 14-15 on the meter at 5k ,your doing good ,and your problem should be solved .did you epoxy the windings ?

13.7 at idle. I did not epoxy the windings, I sprayed them with a special paint the auto electric shop gave me. What kind of epoxy should I use?

Atreyu · 06-10-2007, 3:24 PM

that special paint isn't going to do anything, you need to use epoxy, I don't remember what kind

dattaway · 06-10-2007, 3:27 PM

Quote:

Originally Posted by ratchetman

13.7 at idle. I did not epoxy the windings, I sprayed them with a special paint the auto electric shop gave me. What kind of epoxy should I use?

If it was varnish paint, that's the best.

I have confirmed that smelling the engine oil is the best way to determine if the stator is bad. This bike has given me enough experience.

Renegade929 · 06-10-2007, 4:32 PM

Quote:

Originally Posted by ratchetman

13.7 at idle. I did not epoxy the windings, I sprayed them with a special paint the auto electric shop gave me. What kind of epoxy should I use?

high temp epoxy i would imagine

dattaway · 06-10-2007, 4:58 PM

Quote:

Originally Posted by Renegade929

high temp epoxy i would imagine

JBWeld works great for this. I even use it for brake pad linings on my bikes for the past several years.

*Fastrr* · 06-10-2007, 7:45 PM

I would not charge at 2amps all night. more like 2 amps for 2-3 hours. You don't want to fry your battery if it's still a good one.

After checking out your electrical system, have the battery tested at a shop/store. It may be the culprit.

*ratchetman* · 06-12-2007, 7:16 PM

I have resistance tested my battery a couple of times on the D-tac plus at work. It tests good. After running for a couple of minutes the charging system is producing 15 amps about 4 are going to the battery. This does not seem out of line to me. What do you think?