voltage from retifier varied CA77

Greggie-e · Post by **Greggie-e** » Thu Mar 01, 2012 8:18 pm

That is probably the cheapest, quickest and best solution, I will read up on it today and have a go over the weekend.

The best way I figure is to just follow the wires back from the rectifier until I get to the alternator.

Greggie-e · Post by **Greggie-e** » Mon Mar 05, 2012 5:50 pm

I stripped the back end of the wiring harness.
It is a mess, something has burnt at some stage and a lot of the wires are burnt through.
I need to track down the right thickness and color for all the wires before I perform a repair.
Has anyone used slightly thinner wires in their harness?
I have an abundance of slightly thinner guage wire, but I am thinking it will just lead to problems.

You can see that parts of the red, brown, yellow and blue wires have been damaged.

rzgkane · Post by **rzgkane** » Mon Mar 05, 2012 8:24 pm

Do not go thinner on the wire. Any electronics shop will have the guage you need.

And the good news is you appear to have found the problem. The wiring on these bikes is so simple even a caveman could create a new harness with about $30 in parts.

Greggie-e wrote:I stripped the back end of the wiring harness.
It is a mess, something has burnt at some stage and a lot of the wires are burnt through.
I need to track down the right thickness and color for all the wires before I perform a repair.
Has anyone used slightly thinner wires in their harness?
I have an abundance of slightly thinner guage wire, but I am thinking it will just lead to problems.

You can see that parts of the red, brown, yellow and blue wires have been damaged.

Greggie-e · Post by **Greggie-e** » Tue Mar 06, 2012 9:07 am

I found the right guage at an auto supply store (Super Cheap Auto)
They even had the right colors I needed.

I replaced all of the damaged wires and hooked it all back up....
But I still get the same result.
I have made a video of it here

Does anyone have any ideas on what is going on here?
I am suspecting a broken voltage regulator...

Wilf · Post by **Wilf** » Tue Mar 06, 2012 9:24 am

Unless someone has modified the wiring, there will be no 'voltage regulator' on your machine.

Have your tried a different meter?

Wilf

Greggie-e · Post by **Greggie-e** » Tue Mar 06, 2012 9:43 am

oops I meant rectifier.

there is no regulator on my machine.

No I haven't tried another multimeter, I guess that is next...

rzgkane · Post by **rzgkane** » Tue Mar 06, 2012 10:42 am

Greggie-e wrote:oops I meant rectifier.

there is no regulator on my machine.

No I haven't tried another multimeter, I guess that is next...

I'd try an analog meter and see what you get.

I'd also go through the Bill Silver stator and stator output checks and check the current directly from the source with the battery out of the loop. Set your meter to ACV when measuring current out of the pink, yellow and brown wires.

Is the battery known good?

Have you checked for a grounded stator with the engine running?