Undercharging

[brianinpa]

I rode the bike (1200) for work today and noticed that the battery didn't have as much juice as it should have... labored starting. Once the bike is running, it runs fine, so that more/less rules out the stator the easy way - if the stator was bad, the bike would have quit running when the battery went dead, but that isn't happening... I have experience with that situation and now how the bike acts when that happens. :head bang:

So, I suspect the battery isn't getting enough of a charge from the stator/regulator. I was under the impression that this charging system couldn't undercharge unless the stator was bad. Is that assumption correct?

The other possibility is the starter brushes. Looks like I get to do some work to the bike tonight.

 

[brianinpa]

Have you ever started working on something only to get that discouraged that you stop what you are doing and walk away?

I wanted to install a switch for the fan so that I can control when it runs and when it doesn't. When I was done with that, I was going to look at the regulator... I shouldn't have peaked and looked ahead because this is what I found:

Regulator Mess 2

• brianinpa
• Mar 10, 2016

That doesn't look good, so I pulled the plug, or should I say I tried to pull the plug, because it wasn't moving. When I did get it apart, some of it stayed behind:

Regulator Mess

• brianinpa
• Mar 10, 2016

What could cause that? Something tells me I am missing a wire from the harness of the new regulator that I installed when I replaced the stator the last time:

Regulator Mess 3

• brianinpa
• Mar 10, 2016

No, I didn't cut the sensing wire off, it just isn't there. How did I missed that before... :blush: Now I have some rewiring to do and then hope (and pray) that the stator isn't cooked.

 

[mcgovern61]

Did you wire that plug? Normally, when you see that kind of cooked mess, it is overheated wires from high resistance. That is normally caused by corroded wires.

 

[brianinpa]

Nope. Brand new last Spring. I assume the stator has been over charging because there was no sense wire to signal that the battery needed charged.

 

[dan filipi]

Yeah the same 3 yellow stator wires are there and will overheat if not maintained good like the other plug.

 

[mcgovern61]

Take notice to the red wire pulled out:

My money is on the fact that the crimps were not tight enough.

 

[brianinpa]

Possibly, but they were pulled out because they burnt off. :shock:

 

[brianinpa]

At least I have spare parts on my 84 parts bike... No Vince, not yours! :smilie_happy:

 

[slabghost]

From the look of those wires I'd be tempted to solder, can always reheat the solder and pull them apart later.

 

[Ansimp]

If that is the new regulator wires Brian it looks like poor crimping. When I change these FM style plugs I usually solder the wire after I have crimped them. You should also make sure that you are not drawing too much current with your electrical load ( accesories etc) once you have repaired the plug.

 

[brianinpa]

The only additions I have is a radio and a charging outlet that rarely gets used.

 

[joedrum]

ugly looking ...just got to love honda wiring ...not!!!!

 

[zman]

Still what explains no trigger wire on the regulator?, could it be from another honda maybe.

 

[brianinpa]

zman » Fri Mar 11, 2016 12:47 pm[/url]":141b7rb4]
Still what explains no trigger wire on the regulator?, could it be from another honda maybe.

Inquiring minds would like to know. :headscratch: I ordered it from either Bike Bandit or Motorcycle Superstore with the last stator and it was stated as for a 1984 Standard...

 

[joedrum]

oh my brian ...how could this be that bad ...sheesh the parts out there are really sucking now days

 

[brianinpa]

Replaced the burnt plug and the bad regulator with the parts from my 84 part carcass I have, wired it up, fired it, and reading around 14.5 volts at 3000 rpm.

arty:

Back to the regularly scheduled repair to the fan...

 

[joedrum]

mr luckly ...glad to hear it

 

[brianinpa]

Sometimes it's better to be lucky than good. I'll take the lucky.

 

[Ansimp]

The trigger wire reg needs an ignition feed as a battery voltage reference. The late model style references from the battery feed (red wires). It appears that one faulty crimp on the regulator ( not Mother Hondas wiring Joe) caused your melted plug issues Brian

 

[Denver]

Back to antiquated Honda junk parts huh? :smilie_happy: Glad you got it squared away! :good: