Mechanical question

[seamonkeyaj]

So, I was hoping to pick anyone's brain who might know something about this.... The charging system on my bike hasn't been running right, and we're running out of ideas here. We're continuing to try more diagnostics and repairs and talking to local mechanics, but I figured why not see if someone here has any new ideas. Details:

Last summer: Died in traffic, battery dead. Replaced battery.
May: Battery won't hold charge, bike not charging properly. Rectifier not testing out (no current through the plug-in) - replaced.
July: Battery issues again - new battery.
September: Dropped dead while moving - rectifier red-hot. Determined that it was fried from the stator overcharging. Replaced rectifier and stator with heavy duty after-market. Stator putting out at proper levels, battery charging properly. Rectifier still getting hot.

What to check next???? Why would the rectifier still be overheating?

[PlayfulGod]

So, I was hoping to pick anyone's brain who might know something about this.... The charging system on my bike hasn't been running right, and we're running out of ideas here. We're continuing to try more diagnostics and repairs and talking to local mechanics, but I figured why not see if someone here has any new ideas. Details:

Last summer: Died in traffic, battery dead. Replaced battery.
May: Battery won't hold charge, bike not charging properly. Rectifier not testing out (no current through the plug-in) - replaced.
July: Battery issues again - new battery.
September: Dropped dead while moving - rectifier red-hot. Determined that it was fried from the stator overcharging. Replaced rectifier and stator with heavy duty after-market. Stator putting out at proper levels, battery charging properly. Rectifier still getting hot.

What to check next???? Why would the rectifier still be overheating?

its either not getting air to cool it, or isnt mounted corectly so the heat will disperse into the subframe, or the stator is putting out to much amperage.

[seamonkeyaj]

The local tech that we got a hold of today said this particular rectifier does get a little warmer than some... We haven't even gotten the covers back on yet, so I don't think it's an air flow problem, but I think we're going with the "put it back together and hope it's really not overheating" option. *sigh* I'd hate to fry another one, but maybe this is just how it's supposed to be???

Quick update.... after talking to Michael - he said he hasn't had the rectifier bolted to the frame during any of his testing, so he's gonna do that tonight and see if that keeps it from getting so warm. He's also gonna look for amperage specs on the stator, because he only checked voltage so far.

Thanks so much for the ideas! I felt like there was some "missing piece" to this puzzle, and that might just be it! :)

[ncdixie]

Does your bike have a voltage regulator? My mechanic & husband (D P Cycles) if it does and you don't disconnect it for testing you could get a false reading.
Good Luck! Let us know if you go riding girl!!!!

[seamonkeyaj]

Does your bike have a voltage regulator? My mechanic & husband (D P Cycles) if it does and you don't disconnect it for testing you could get a false reading.
Good Luck! Let us know if you go riding girl!!!!

The rectifier is technically the voltage regulator in this application. We've got bad storms coming through here for the next few days, but as soon as those clear up, he's gonna try and take it out for a test run and see what happens! :)

[Ninjachic]

The rectifier is technically the voltage regulator in this application. We've got bad storms coming through here for the next few days, but as soon as those clear up, he's gonna try and take it out for a test run and see what happens! :)

I hope it works, nasty storms for sure but did you see the forcast for this weekend? Sun 80's yahooooooooooo. I'm loving this looonnng "Indian Summer"

[ncdixie]

Storms? Send some rain down south will ya? It's so dry here. Everything is a dust ball.
Best of luck with your bike. Having it broken is a pain in the ass and depressing especially if the weather is nice.

[seamonkeyaj]

Yeah, you ain't kiddin'!!!!! Especially when I NEED a vacation about now (not just want, NEED), and can't take it! lol

[ncdixie]

Yeah, you ain't kiddin'!!!!! Especially when I NEED a vacation about now (not just want, NEED), and can't take it! lol
Hang in there your downtime will come!! I do so know what you mean.
My husband flipped the polaris over in the mtns in July. Broken femur, air lifted to TN, screws in hip, then he fell again i the shop broken again, long rod and lag bolt in place of the screws. I havn't done crap this summer, I am in such a need for a vacation myself. ugh.
You got some love over here though!!!!

[seamonkeyaj]

Well, the b/f promised me a trip to the east coast at some point soon (as soon as he can get the time off work, we can get the $ together, and the kids are on visitation). We're planning to go through NC, and then down to Myrtle (he used to live there). I'll let you know if we manage to head your way... ;)

Anyhows~ We took the bike to the shop, but they were too busy to take it. The mechanics all said the same thing, though - the regulator on that bike is supposed to get warm, and we've already replaced everything, so no one even has any idea what else it could be, since it's charging properly. So, I'm riding, and we're keeping a close eye on the charging for now. Got to ride to work this morning! A little chilly and damp out (about 39 when I left the house, and it rained all night), but it was still awesome to be out! Yippee!!!!!