I can't seem to fix this damn charging system. Replaced the R/R, stator output is fine, no melted connectors, battery is fine. I brought it into the shop and they "tightened up some connectors" and told me it was working (still wouldn't charge at idle, but did around ~3000rpm). Rode the bike for an hour fine, took it for a 5 minute trip, wouldn't start. Bump started it without much trouble and got it home, threw my multitester on it and it still says ~12.5v charging rate, even at 5000rpm. I'm fed up already - what the hell is wrong with the charging system on this bike?

 

Inspect the conectors from the stator and r/r very closely for tightness inside the terminals themselves, as well as inspect the wires for any nicks or cuts that could have allowed moisture in there and caused corrosion. Poor ground or loose connections is usually the culprit in most electrical problems.

 

Going to do a full inspection of all the connectors, clean and tighten them, then reconnect with dielectric grease. Might throw a little voltmeter on there so I can keep an eye on the issue as well. Hoping this gets her running!

 

How is the battery? I had one that I just replaced last fall pack it in already... it just won't hold a charge. I am in the same boat...start with a new battery and start the diagnosing all over.

 

The battery is fine. Here's something interesting though. When the stator isn't connected to the rest of the circuit (not plugged in to the R/R) all three pins output the proper voltage. But when it's connected to the rest of the circuit, one of the stator pins outputs a really low voltage and the other two push to compensate. I imagine each pin corresponds to a phase of the stator? Ideas? Anyways, cleaning the contacts and everything got it up to ~12.8v charging. I would like to get it up to ~13.5v, ideally.

 

did you meaure the ohms through the three alternator wires? then check the three wires to the voltage regulator. i forget the values, the manual has them, but they should all be similar. might help narrow down a problem with the alt...

 

second that, with your bike NOT running the resistance between all of the contacts should be within decimals of each other.

 

Third. Ohm out the stator connections. It sounds like one of the phases of the stator is having issues under load.

You're correct that each pin corresponds to a phase of the stator.