Bike shut off while riding

[dschmitta]

Hey everyone, looking for help. Did h/light relay override. H/light works great. After doing this, went for ride, noticed lights dimming, turned around but didn't make it home. Recharged battery and took for cell check, o.k., so bike not charging. What should I check now? Heard that there is a wire behind fuse panel that can break and be charging problem. Is this true and should I check there? Thanks

[natemoen]

Yup, there is a plug behind the fuse panel that comes from the alternator and that gets coroded and overheats and then melts. 9 times out of 10 that is the problem. Check that first.

[dschmitta]

Yup, there is a plug behind the fuse panel that comes from the alternator and that gets coroded and overheats and then melts. 9 times out of 10 that is the problem. Check that first.

Do u happen to know what color wire is and how hard it is to get to? Should I unplug neg terminal before messing with this? Thanks

[natemoen]

It is always safest to unhook the neg terminal.

Don't remember the wire colors, I think it is 3 whites and another color going into it, but just follow the wires coming out of the right side engine cover.

[skids]

3 whites and one yellow, but over time, they may all look about the same color...

[dschmitta]

checkin plug

3 whites and one yellow, but over time, they may all look about the same color...

going out now to check alt. plug. Keep u posted. thanks

[dschmitta]

checked wires

checked wires followed uo from alt. 3 white, one yellow, all tight, nothing burnt, loose or corroded. checked battery voltage and was only showing 11.6 at 4k, bout the same at 3 k. Any Ideas what to do next. Thanks. Dave

[bikerphil]

Tap into the green field coil wire that leads to the alternator and ground it and with the bike running, rev to 4K and measure your voltage again. If it increases to 14+, your regulator is bad.

[dschmitta]

will tap

Tap into the green field coil wire that leads to the alternator and ground it and with the bike running, rev to 4K and measure your voltage again. If it increases to 14+, your regulator is bad.

Will do and let u know. By the way, where is this green coil wire and where di I ground it to? Sorry

[bikerphil]

There are 2 harnesses coming from the alt. and they run up behind the fuse panel, one has 3 white wires and one has 2 wires, the 2 wire one has a brown and a green wire. Tap into the green wire at the plug or strip off some insulation and twist a jumper wire around it and run it to a part of the frame that is not painted, like a bolt. Have your meter hooked to the battery and with the bike running, touch this jumper wire to the frame ground and check your meter for an increase in voltage. This test bypasses the voltage regulator and will allow the alternator to produce full voltage, this is safe for temporary testing purposes.

[dschmitta]

There are 2 harnesses coming from the alt. and they run up behind the fuse panel, one has 3 white wires and one has 2 wires, the 2 wire one has a brown and a green wire. Tap into the green wire at the plug or strip off some insulation and twist a jumper wire around it and run it to a part of the frame that is not painted, like a bolt. Have your meter hooked to the battery and with the bike running, touch this jumper wire to the frame ground and check your meter for an increase in voltage. This test bypasses the voltage regulator and will allow the alternator to produce full voltage, this is safe for temporary testing purposes.

I've seen the wire, I'll ground her out and let u know. much appreciated.

[dschmitta]

checking wire

Have jumper wire I made with clips on ends. Would it be okay to clip one end to green plug prong or should I strip insulation on green wire and just clip this jumper to the exposed wire and then just clip other end to unpainted metal? Thanks

[dschmitta]

did test

Grounded out green field coil wire, ran bike up to 3-5k and voltage never moved. Stayed steady at 11.5, 11.6. Does this mean alternator o.k.? Any idea what to try next? Thanks. Dave

[bikerphil]

Ok, you tapped into the green wire and grounded it (this is with the plug still connected) and there was no change in the voltage correct? If so, then I would suspect the stator (alternator) to be NG. There is a diagnostic check for the stator and field coil in the FSM, I would try that test next. If it fails, I would just buy a complete used good unit from member Andreas.

[dschmitta]

Ok, you tapped into the green wire and grounded it (this is with the plug still connected) and there was no change in the voltage correct? If so, then I would suspect the stator (alternator) to be NG. There is a diagnostic check for the stator and field coil in the FSM, I would try that test next. If it fails, I would just buy a complete used good unit from member Andreas.

I unplugged it first. I then ran jumper from green wire prong to bolt, started engine and revved. I take it the plug was supposed to stay together? My mistake. I did notice the tach was just bouncing a little while I did this, it didn't move mush off of zero? Should I just do it again