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**neJeff** · 07-16-2011, 02:35 PM

Well I spoke too damn soon again! It was fine for 6 days in a row. I had a voltmeter wired to it and it was charging well and light was coming on fine. Took a 50 miler this afternoon and about 2/3 thru I stopped for a water. Light did not come on when went to leave and the bike did not "feel" the same. Too bad I took the voltmeter off for the the trip! Maybe the old regulator was getting to hot ( it's 100 degrees out right now). Going to wire up my voltmeter for some "live" testing and tonight when it cools to say 80 I'll try again. When the regulator stops producing and the ignition is running off pure battery can the bike run differently or is it in my mind. Thought it was feeling different...I don't know.

**TopCatGr58** · 07-16-2011, 04:54 PM

It's very possible that the seat of the pants feel is different, due to weaker spark from voltage drop across system wiring. The same Stronger feel those of us have gotten when we put in the High Output coils, very strong spark in all rpm ranges. Good Luck trouble shooting.

T.C.

**crazy steve** · 07-16-2011, 06:48 PM

Jeff, those alternator connections nearly drove me crazy.... well, crazier

Check your connections by testing between the regulator output and the battery positive post. Insert one test lead into the regulator side of the plug at the regulator (don't disconnect it, stick the lead in where the red wire goes into the plug), then put the other on the battery. With the bike running at about 2K rpm, you should get a reading of less than .1 volt, the less the better. More than that, and you've got poor connections between the two points. Places to check are the regulator plug, the 'main' fuse, and the red wire that goes to the positive battery cable, and of course the battery cable to battery.

You can also check between the output and ground to see if the charging system is actually putting out enough power. If output is low, you may need to re-clean all the connections to the alt coils. To check these, first check coil resistance at the plugs behind the fuse box to make sure they're within spec. If they are, plug these back together then check the same wires at the regulator plug. If the resistance numbers go up at all, those connections still aren't good enough. If all this checks out good but output is still low, you can jumper the green wire at the regulator to ground (bypassing the regulator) and you should then see voltage go up according to rpm.

Still no or low output? Bad regulator....

**neJeff** · 07-16-2011, 08:16 PM

Steve, Well I am pleased to report I am somewhat of a moron. Went to put the battery charger on it tonight so I could do some testing tomorrow and apparently when I took my voltmeter leads off from my "live" testing I failed to properly tighten down the negative battery cable! It was loose as a goose and I'm damn lucky it didn't come completely off on me today and leave me stranded. I tightened it up, started it up and sure enough light popped back on and it's operating properly again (knock on wood). I'm so glad this was my screw up and not further issues.

**crazy steve** · 07-16-2011, 11:26 PM

Originally posted by neJeff View Post

Steve, Well I am pleased to report I am somewhat of a moron. Went to put the battery charger on it tonight so I could do some testing tomorrow and apparently when I took my voltmeter leads off from my "live" testing I failed to properly tighten down the negative battery cable! It was loose as a goose and I'm damn lucky it didn't come completely off on me today and leave me stranded. I tightened it up, started it up and sure enough light popped back on and it's operating properly again (knock on wood). I'm so glad this was my screw up and not further issues.

Hey, we've all been there.....

Glad it's fixed!

**neJeff** · 07-18-2011, 01:39 AM

Spoke too soon again. Worked fine in the morning but later in the day back to it's old tricks....frustrating!

**neJeff** · 07-18-2011, 04:04 AM

Can something be loose under the stator cover? Took it to work this morning to see if the cooler (slightly) temps had any effect and it was still not charging. I swear I am hearing funky noise from underneath the stator cover, kind of like rattling. I have never had the cover off, is there anything physically under there that could be loose or causing noise or cause the charging system not to work. I have ohm tested stator wires multiple times and always is within spec but that is when the bike is not running.

**crazy steve** · 07-18-2011, 11:29 AM

There could be something loose...

It's not a big deal to pull the alt cover and look; it's 'dry' under there so you won't lose any oil. But don't run the bike with the cover off, as there's a oil passage that the sealing plug can pop out as the cover holds it in place. This will spew oil everywhere if it comes out..

About the only thing that could be loose and affect charging would be if the rotor is loose on the crankshaft. Hopefully that's not it, as the rotor/crank connection is a precision taper fit and if that's damaged you might not be able to get the rotor properly tightened. The rotor is held on with a single (8mm?) bolt, make sure it's not loose. Torque number is 47 ft-lbs.

**neJeff** · 07-18-2011, 01:31 PM

Ok, going to check it today...I'll report back

**neJeff** · 08-03-2011, 09:33 PM

Okay, I'm two weeks overdue on checking back and still haven't had cover off yet but I know one thing for a fact...whatever is going under that cover is my issue. It has been working 85% of the time but everytime you start the bike the rattling underneath cover starts and as soon as it quits the lights pop on. This could be right away or it could take 10 seconds. When the rattle doesn't quit no charging is to be had. I shut it off and try again. I am going to peak very soon and see what's what but been busy with other more pressing matters

**neJeff** · 08-04-2011, 08:05 PM

There was one very loose bolt under the cap on left side that was holding the coils. Tightened it all up and no more rattle, also no more headlight

**neJeff** · 08-06-2011, 07:41 PM

Ever since I tightened the loose bolts that held the windings of the field coil I can't get any juice. Will need to investigate further...any thoughts out there?

**bikerphil** · 08-06-2011, 10:36 PM

Try tapping into the dk. green field coil wire and grounding it and see if it charges. Did you plug all the alternator connectors back in? Did you perform any diagnostic tests as described in the service manual?

**neJeff** · 08-07-2011, 06:14 AM

Did not unplug any. Just took out the screws, checked underneath and tightened them up. Going to check ohms AGAIN today.

**rpgoerlich** · 08-07-2011, 06:25 AM

So is the system charging? It sounded like it was, just the headlight not coming on.
The headlight RELAY is activated from one of the white stator wires. In the wiring harness just before it gets to the headlight relay under the tank, there is a DIODE. Most times it's either good or bad but I have had one that was intermittent. If you follow the wire in the harness from the relay going toward the rear, You'll find it in a plastic tube. I got a replacement at Radio Shack and soldered it back into the bullet connectors used in the harness and slid it back into the plastic tube. Headlight problem fixed.

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