Regulator rectifier woes. Help!

[CookMySock]

Sorry, but at least 50% of that sounds like a load of hogwash.

Pull your stator cover off and see for yourself. I'd put money on all your wiring being in great order, and there being one tiny fault to ground inside one of the windings causing all the problems. You MIGHT get away with just removing the faulty winding and replacing it, but I'd be tempted to rewind the whole thing.

You should at least do some basic continuity checks and insulation checks. Two minutes with the tester will tell you all. If you meter doesn't read down to low ohms, you might have to unsolder the star connection to isolate which winding is at fault.

Steve

[vifferman]

Sorry, but at least 50% of that sounds like a load of hogwash.

Having replaced two R/Rs, and read countless tales (and seen numerous photos) of other failures, it sounds pretty reasonable to me. Most R/R failures seem to start with corrosion at the plug between the R/R and wiring loom, with a much smaller number being stator based, and possibly due to heat or crappy manufacture. In either case, one or more wires get crispy, the insulation breaks down, and something shorts.
The first R/R I did however had zero visual physical signs of anything amiss. After it was replaced, I decided the whole charging system apart from the stator was crap, and cut out everything from where the stator wires exited the case, right through to the battery. I removed all plugs, and hard-wired everything. I gained over half a volt from that alone. I also relocated the R/R to under the headstock (where the horn normally lives) on a 4mm aluminium plate. Wires went from the stator to there, then from the R/R to the battery. An extra ground wire went to the main wiring loom so there was some redundancy.
So, effectively I did what this guy recommended (although I'd never come across this or a similar tale till just a few minutes ago).
It sounds like good commonsense to me.

[ralley]

Sorry, but at least 50% of that sounds like a load of hogwash.

Nope, it is spot on. Have been down this road myself with my 92 750SS as have many SS owners. Very well known, well documented problem.

Rob.

[Kickaha]

Nope, it is spot on. Have been down this road myself with my 92 750SS as have many SS owners. Very well known, well documented problem.

Rob.

I think you will find it even goes back to the Bevel drive twins, Ducati must be slow learners