Alright guys having some trouble with my bike. To avoid a long story here are the details that are important.

-Bike stalled on way to class (battery flat. wouldnt start electrically or push)
-Put in new battery
-Helped to start but eventually killed the battery
-Multimeter discovered that the battery wasn't charging
-Measured resistance across stator wires and got a constant ~0.4 ohm off each.
-R/R replaced with 2002 GSXR unit
-Still no charging.

So yea I'm pretty stumped. Gave the battery a full charge over the last day off of the bike and put it back in this evening. Fired right up and let it warm up. Monitored with multimeter and getting about 1/2V drop every 5-10 minutes. When revs brought up to ~5k the voltage goes down about 1/2V also. Also noticed the plug between the R/R and stator is EXTREMELY hot. I thought I actually saw it puff some smoke for a second. But all pin connections still look good. Could the plug be the issue though? Help a newbie out!

 

There are 2 plugs between the R/R and the Stator behind the Alternator Cover. Which connector are you talking about ? The one that has 5 wires that plugs (or used to) into the R/R itself, or the 3 pin connector up by the battery/Starter Relay ? Anytime a connector is getting hot, it means there is resistance across that connection. This can be either poor/loose connections or the wires themselves are loose in the pins of the connectors. There is a pretty significant amount of current running through those wires so good tight connections and clean connections are important.

If you're not getting a charging voltage across your battery when your engine is running at 5K RPM, there is not much it can be. If your yellow wires check good as you say, then you probably have a bad R/R. First make sure your connections are good though. You could be getting a voltage loss though those connections.

 

https://cbrforum.com/forum/f2-tech-9...-solved-27739/

http://www.triumphrat.net/speed-trip...r-upgrade.html

Sounds like you've got a fair grasp, these might help out. IDoDirt's the man.

Ern

 

I had the same problem. Thought it was the R/R, but it turned out to be that the 3-pin connector had melted and there was no connection.

 

Hey guys thanks for the replies. Finally was able to dig into the bike now that class has chilled out for a while (Mechanical Engineering major=no freetime). Somehow when the Reg/Rect died the main fuse from the battery also blew so that explains the no charging after the R/R was replaced. Charges like a champ now! Now to figure out the ~5k hesitation... lol. Project bike fun times! Thanks for the help