I have had an idea with regrds to the regulator/rectifier.

One of the many problems this bike is overcharging. The battery get 15V but can only handle 12-13 so the excess goes as heat which boils the batter and sulphurs the plates.

The R/R is supposed to cope with this but clearly doesn't.

Some bikes have a seperate Regulator. So why not put one of these and attach it to the battery and the other to ground and take the load off the R/R?

 

What about a surge protector on the battery?

 

Hmm, I also noted that the voltage seemed to be very high on my -92 Hurricane. I never measured the voltage but understand itto be veryhigh since the Yusa battery was always wet on top and needed to top with water quite often. The battery was also halfbad, so I installed a new low priced GEL battery that worked OK. GEL batterys are sensitive to overvoltage though,so I guess it will not last for verylong.

What I wouldtry on aHurricane in case the measured voltage is more than 14.5 Volt, at the very maximum, would be to discard the Honda R/R and install a Yamaha R1 R/R unit. They are well known not to fail like Honda units. Itappears to be a R1 R/R on my Bird that has been installed by previous owner. The voltage is very mild, stays at about maximum14 volts when the rpm is so high that the voltage doesn't climb any more.

Linky: http://www.vlc.com.au/~justin/about/...g_replace.html