Bike is a 97 cbr900rr.Well I was having some trouble with my charging/starting and after going through a few things I came to the regulator/rectifier. Now the top leftyellow wire (connector)on the plug and unit is burnt. What I need to know is if the unit could do it to its self or did something else send a surge or something through it and burn it up. Basically I don't want to spend the money to replace it for it to just go out again. I checked the unit and plug with a multi meter but I'm not that great at reading one and also in my manual it says some multimeters will give a false reading on the r/r anyway. It did read voltage from the hot wire on the plug though.

 

Mine was burnt( yellow wires ) too. I think that it is because of the extreme heat from the rectifier but not sure. I did buy a new one and change the wires. Even my connection was melt down. I never had a problem after that.

 

OK so i'll go ahead and replace them. Hopefully everything turns out ok.

 

If you buy some after market wires, Make sure that they are the same size. If they are smaller, you will have some over heating issues again.

 

I've read a lot about people having this problem with all years of 900RRs. On another sight, I read that the R/R makes a very poor ground connection to the subframe, via the casing on the R/R. By their recommendation, I ran an additional ground wire from one of the bolts that hold the R/R to the subframe, to the negative battery wire, where it bolts to the motor. I have not had any problems with the R/R on my 96 yet, and did this ground wire thing to it.

For the minimal cost and installation difficulty, It's worth a try.

There is a web site, www.electrosport.com, that you can download a trouble shooting block diagram, for diagnosing charging problems. All you need is a volt/ohm meter.