Not charging - again...

dcstrom

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A couple of years ago I had a problem with the bike not charging... this was at about 120,000 miles. I chased it, with friends, for a week, thinking it was the regulator, probably... I checked the stator but the resistance numbers are so small that I didn't have a multimeter that would give me an accurate result.

So this time I'm waking up the bike after winter in the UK, hard to start, quelle surprise, got it going eventually with a battery-booster. Took it up the road, check engine light and ABS lights come on. From experience, this is what happens when the battery doesn't have enough juice to run the bike, just before everything shuts down.

Had to push it back, check DIAG codes - code 19 - clutch or sidestand switch. That's all. Bought a new battery (this one is nearly 4 years old), charged overnight, today fired up ok but does not appear to be charging. Voltage does not increase with revs. Code 46 popped up too (charging problem duh). This is checking at the battery, but instructions to check the regulator say voltage should be checked at the connector, so I'll do that soon, but probably no difference between checking at the regulator and checking at the battery?

Checked the stator with the multimeter - same problem as before really, don't have an accurate enough multimeter for a proper test.

Cleaned some contacts, and thought the easiest way to check the stator was to just look at it - last time it was badly burned and obviously shot. Not this time, looks OK.

I'll continue checking some things, and hopefully someone with come up with a better idea meanwhile!
 

EricV

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Check your grounds and connectors for loose/corrosion issues. If the stator is doing it's thing, that excess wattage should be dumping to heat if it's not charging the bike. Off hand, w/o getting a chance to refer to the FSM, I would guess Regulator/Rectifier since the stator visually looks ok.

OEM Stator? Or aftermarket? Some of the aftermarket stators have been known to be flaky with various issues that may not be obvious visually.

I'm out of town now, but I'll check back in a few days when I get home and look up charging issues in the FSM if you need me to.
 

dcstrom

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Check your grounds and connectors for loose/corrosion issues. If the stator is doing it's thing, that excess wattage should be dumping to heat if it's not charging the bike. Off hand, w/o getting a chance to refer to the FSM, I would guess Regulator/Rectifier since the stator visually looks ok.

OEM Stator? Or aftermarket? Some of the aftermarket stators have been known to be flaky with various issues that may not be obvious visually.

I'm out of town now, but I'll check back in a few days when I get home and look up charging issues in the FSM if you need me to.
Thanks Eric - yeah OEM stator. When you say "dumping heat" you mean from the regulator right? Didn't notice but will check when I get running again. Meanwhile will continue checking/cleaning... it was running fine when I parked it in October, so gotta be some corrosion somewhere right?
 

EricV

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Yes, heat at the regulator. If those fins are not warming up when the bike is running, I would guess no output from the stator. Check the simple stuff first! So a un-seated connector or corroded connector or ground could be a simple solution. Which would make sense under the conditions you describe, working before storage and a long storage period. Any chance rodents got to the bike and chewed thru some wiring?
 

EricV

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Unplug the stator wires.
put AC volt meter to each white wire and ground.
should read 80 volts at 3000 rpm.
Nice info! And make sure you're set to AC voltage on the meter!
 

dcstrom

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Yes, heat at the regulator. If those fins are not warming up when the bike is running, I would guess no output from the stator. Check the simple stuff first! So a un-seated connector or corroded connector or ground could be a simple solution. Which would make sense under the conditions you describe, working before storage and a long storage period. Any chance rodents got to the bike and chewed thru some wiring?
no sign of rodents, and if there were, my mate who has 5 other bikes stored in this shed, would be right on top of it! I'm sure of that...
 

Jlq1969

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Remember set AC before regulator/rectifier....and DC after this, or in baterry
check also that there is “no”continuity between the wires of the stator and the chassis, with the engine “off”
 
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dcstrom

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That stator cover is a bitch to get back on isn't it? Thought it looked simple, but then didn't allow for the strong magnets grabbing both the gasket and parts of the cover and making it tricky to get things lined up #newproblemsyoudon'tneedwhentryingtofixadifferentone
 

dcstrom

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Ok the visual inspection of the stator was probably not the best idea I ever had! What a pain in the arse to get back together. Would have helped if I'd had a new gasket that would sit flat against the case...

Anyway... after getting the stator cover back on and cleaning a bunch of connectors, it now appears to be charging. Only one slight concern - I'm reading 14.1v at idle, and 14.1/14.2 at 5000rpm. Hardly any change. Normally I would have expected 13.5 or so at idle, and 14.5 at higher revs. Any problem here? It's a brand new battery if that makes any difference.

Diags are still showing Error 19 even after cleaning clutch and sidestand switch. No more Error 46 though, which is a big step forward haha!
 
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EricV

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Hmm, I wouldn't be too surprised at 14.1v, but would check visually that all my bulbs look normal and are working. But yes, I too would expect lower at idle and some change as the rpms come up. Keep in mind cold idle is higher rpms, by a little. My gen II has 14.5 at idle, but I'm running LED headlight bulbs and marker lights. The Gen I normally was about 14.2 and would go up when I had a burned out bulb.
 

WJBertrand

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If it helps, I have a volt meter on my bike and it charges about the same at idle as it does running down the highway. Varies day to day from 14.2 - 14.5V typically, but not by RPM much if at all.


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dcstrom

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If it helps, I have a volt meter on my bike and it charges about the same at idle as it does running down the highway. Varies day to day from 14.2 - 14.5V typically, but not by RPM much if at all.


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Yes that helps. I'm guessing a new battery plays into the equation as well.
 

Nikolajsen

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With my bikes voltmeter, it shows 14.1 at idle and doesn't really move much more then that... Your OK!
I'm also surprisedo_O.
But seems to be normal....first bike I ever see, that did this.
But I believe you, when you write it:)
 
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