Charging problem

[CantRemember]

Hi,
The bike is a 1993 Honda CBR900RR
Because of my lack of attention, the battery went bad last year. I think it buggered up the alternator or rectifier because after installing a new battery there seems to be no charging happening. After charging the battery with a battery tender, I can get to work and maybe start it for the trip home. But it is acting as a 'total loss' system.

Does anyone have experience of this kind of problem?
Any suggestions would be gratefully received.
Thanks,
James

[bugjuice]

possibly a dud replacement battery..??
welcome btw

[Biff]

When you rev the engne, do the headlights get brighter, then dim afterwards?

If so, and if it's not a dead battery, odds on its the recifier. A common problem with the older rectifiers due to there being no heat sink fitted (or a very small one) and not enough air flow to keep it cool.

You'll be able to tell the older rectifier quite easily as it wont have a lump of metal with fins strapped to its back.

How handy are you with a volt meter? It's pretty easy to check whether its cooked.

[zadok]

Sorry, can't help you with your question, but welcome Pom in the U.S of A to K.B

[CantRemember]

Thanks for the welcome!!
I think the battery is ok. It will get me going and keep me going as long as I dont go too far. I just have to charge it every time I get home. California bikes have the headlights wired on permanently - a good thing for safety - but drains the battery.

I guess I am being too much of a cheapskate to go get a shop manual and figger this problem out !!
Cheers,
James

[CantRemember]

Blimey!! this is amazing!! So many respones in such a short time.
I will be wearing my KB tee-shirt tomorrow as a sign of respect.

Ok, Biff, I am real handy with my digital VOM. Where exactly do I go look for the rectifier?
Sorry for the dumb question, but I have not had to work on this masterpiece of machinery until now.

Thanks folks,
James

[Motu]

Having the lights on helps the reg because it doesn't have to dump the excess voltage,the lights take that up.Hook up a volt metre and give her a rev - over 5000rpm you should be seeing something like 13.5V or more,up to 14.5V...over 14.75 and it's another reg symtom,overcharging.Getting fancy hook a DSO into the wires out of the alt,these should show a nice sine wave and shows the alt coils are working before the rectifier gets hold of them.

[pete376403]

Have a look at the "stator papers" on http://www.thegsresources.com/gs_garage.htm

This is a GS Suzuki site BUT the information given here is applicable to all types of bikes. Folow the fault finding chart and you will find the fault.

[Artifice]

can also be caused by loose connector block or a wire thats not quite in one piece anymore.

[CantRemember]

Thanks for the link to the stator papers Pete, that helped a lot. Testing the stator for continuity and ac output seems like an excellent way to go. It's just a bit loud to do in the evenings. And the advice for checking and tightening all connections is good too - especially on an old bike.

I will do some testing over the weekend to see if i can narrow the problem down. I'll let you know how it goes....Thanks again.

[pete376403]

Hope it helps. Incidentally one of my friends replaced the stator on his Fireplace a few weeks ago - importing an Electrex unit from the UK to New Zealand was still about half the price of the genuine Honda unit.
http://www.electrexworld.co.uk/

[CantRemember]

Found the problem!
Where the stator connects to the wiring loom under the front seat, the three-way connector was badly melted. Cut and stripped the three yellow wires from the stator and checked them for continuity - 0.6 on all three coils (damn!). Started up the motor and checked for Vac output from stator: 60Vac on all three coils at 4,000 rpm (double damn!)

So the stator is ok - bless it.

Had a hard time getting the connector off the rectifier/regulator. No wonder. One of the yellow wire connectors was melted. Tested the RR using the GS stator papers method involving the diode test setting of the digi-multimeter - sure enough one leg to ground was bad. So I need a new RR.

Electrex have a dealer here in California, but they wanted $154 plus $15 shipping plus CA sales tax. The one from the Electrex in the UK is $117 plus $16 air mail, so I ordered it from the UK.

Pete, thanks again for the two absolute gems of information, the diagnoses and the parts supply. I owe you a pint or two for that.

Fireplace - I love it! I took a few photos of the carnage and could post them on my website if anyone is interested. But then, I'm sure you have all seen melted connectors and wiring before

I hope to report back about a fully functional charging system on my bike in about a week or so.

Thanks for everyones help,
James

[thepom]

Sorry I,ve just read your symptons and would have said the same as regarding to the electrex web site.I had same probs but ordered my parts thru electrex in the USA.Top tip is some people fit a CPU cooling fan from a computer wired in to their light system to constantly blow cool air onto the RR.Try www.VFRworld.com and put in RR problem and you ll find loads of RR probs and solutions.Good luck.The pom.

[WINJA]

THE TERMINALS FROM THE ALTERNATOR TO THE RECTIFIER BURNOUT EASY ON THOSE CHECK FOR SCORCHING IN THE WHITE CONECTOR BLOCK

[pete376403]

Sorry I,ve just read your symptons and would have said the same as regarding to the electrex web site.I had same probs but ordered my parts thru electrex in the USA.Top tip is some people fit a CPU cooling fan from a computer wired in to their light system to constantly blow cool air onto the RR.Try www.VFRworld.com and put in RR problem and you ll find loads of RR probs and solutions.Good luck.The pom.

I made an extension cable and remounted the r/r up under the steering head, from its previous location buried under the battery tray. It's a moot point whether it's going to be anymore reliable up there (this IS a GS Suzuki, after all) but I know that, if nothing else, at least it's getting cooled better. The fan idea is good but to my mind it's just something else to go wrong.