[jedwa1216]

After two days of trouble shooting and reading this forum, I must ask for help.
The problem is no charging voltage at the battery. I have performed the three tests in the manual: 1). charging voltage is 0 no matter what RPM
2). Alternator charging coil checks good
3). regulator/rectifier has good battery voltage, good ground and yellow wires have good resistance (.5 ohms on all three) and no grounds.

Can I check the AC voltage coming from the alternator? what is it supposed to be?

Can I check the DC voltage coming from the rectifier?

I would like to narrow this down rather than play the swapping parts game...

Also I have a known good battery. thanks for any help you can give me.

 

[Pain]

If you've been able to check all the parts but get no voltage at the battery, then of course the obvious guess is a bad connection from here to there.

I can't be more specific without having a diagram, but there's an open circuit from the connection for the alternator/stator to the battery.

Because you've been so thorough, I'm certain you've checked all the fuses.

 

[jedwa1216]

I did check all the fuses. any ideas on where to start chasing wires?

 

[shadetree]

are you sure you checked the charging side of the stator ??..and not the firing side ?..make sure you checked the right wire connection..it should go from the stator..to the reg/rec...with a multi meter..start the bike up..set it on 12v dc..put the leads on the battery..rev the bike..the voltage should increase as you rev the bike..if not...it would say your reg/rec is bad..or your stator.

 

[jedwa1216]

Right, the problem is figuring out which one is bad. is it the stator or the reg/rec. can I read AC voltage coming from the alternator? if so how much should it be? should this machine run with the alternator (the three yellow wires) disconnected? thanks.

 

[shadetree]

Right, the problem is figuring out which one is bad. is it the stator or the reg/rec. can I read AC voltage coming from the alternator? if so how much should it be? should this machine run with the alternator (the three yellow wires) disconnected? thanks.

if you have service manaul..it should show you how to check the stator..while it's in the bike..unplug the round green connector comming from the stator..ohm it..compare the specs to what you get...and what the manual calls for...i don't think the bike will run with all the yellow wires unplugged..1 or 2 or those wires is for your spark..the other wire that comes from your pulse generator only sends a signal to the c.d.i..to let the coil know when to fire the plug..you still have to have voltage to go from the stator..reg/rec..then to your c.d.i..then to coil..then to plug for spark...if you test your stator like i mentioned earlier with the multimeter..replace the reg/rec with a good known working one..if your meter shows no voltage..then thats your problem..save the stator for last..they are higher in price to replace. there should be a test you can do on your reg/rec in your service manual.

 

[jedwa1216]

ok, i have narrowed it down to this. the stator is good. and you are right, one yellow wire must be connected to go to the CDI. the reg/rec is also good. several checks have verified that. the problem is with the ground wire going to the reg/rec. if i disconnect that green wire going to the reg/rec i can read 14.5 volts at 5000 rpm coming out of the reg/rec.
now, what does that mean? when I read continuity to ground from the green wire to ground it checks good. i know this is basic electrical theory but I don't understand that enough to compute this problem in my head. does it mean that something downstream from the reg/rec harness is shorted to ground? if so, why doesn't that problem show up somewhere else?

 

[jedwa1216]

i took the reg/rec to the shop today and it turns out the diode inside it is bad. I am thinking that it went bad a few months ago when I found a main power wire in battery compartment was broken. it must have been charging without a load for quite a while, which I hear is not good for them. I will let you know once i get a new one on it. thanks for your help.