Hi
Im having problems with my 748 sp battery not charging, have noticed the wires etc blackened and slightly melted, would the regulator be the problem?
aNDY
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Use volt meter on battery and see if regulator/rectifier is fully charging battery. Should read over 13 volts at about 2500 rpms. if not , bad re/rec. If it does, then it's probably bad battery, take to local shop to test. Should be a free test at places like Autozone, Pep Boys etc.
You should find the fuse box under the hood , most probably beneath the sterring in the right hand corner.
I would recommend you to replace the blackened fuses and replace them with the appropriate fuses that are required as per their voltage.
There could be another problem which is bad earthing or grounding box, or the earthing box is not properly fit in it's place , you should check the earthing box in the bonnet and then check if there are any wires that have got carbon on it and then clean them with polish paper and connect them again.
Check all connections to see if they're loose and check the wires that go to the voltage regulator to see if it's not unplugged a bit, had problems with mine and the wire in front of the bike by the rad was slightly disconnected,wouldn't of notice if i didn't check every wire plug-in, fixed my problem, i also had the battery blinking on the the dash. hope your voltage regulator is not shot.check your battery with a meter (12.4-12.5) is good.
FOLLOW ALTERNATOR WIRES AND BATTERY POSITIVE FEED WIRE.IT WILL TAKE YOU TO THE VOLTAGE REGULATOR BOX.CHECK ALTERNATOR FUSE.IF YOU HAD WIRES TO BURN AND MELT.MORE LIKELY YOU HAVE A BLOWED FUSE.
The charge system is regulated by voltage. amps is not such an issue unless extra lights etc are fitted
Battery voltage
12v - 12.6v with the engine stopped. This should rise to around 13.5v with a couple of thousand revs. If it doesnt rise there is a problem. ( an innocent jump start from the car battery can spike the regulators on some bikes)
The heating up would be normal as relatively, high current is passing through these wires/terminals not only to charge the battery but to power the electrics of the bike. If the regulator is working correctly, it would soon dwindle down since presumably the battery has been charged. Almost always, the connector used is not plastic but phenolic or epoxy based due to this very reason. Another possible reason for excessive heat is that the terminals are not tighly fitted to its counterpart connector. A loose connector would result in a slight voltage drop but high current accross the connection.
Offhand, it is a known/common failure of the regulator. This is especially so for those models with 2 phase alternators (2 yellow wires). The charging current is shared by only 4 diodes (rectifier). I have replaced in my 907 with 3 phase (3 yellow wires) effectively increasing the diodes to 6 thereby distributing the current and lessen the heat build-up. The charging also improved as noted by brighter headlights. In the 907, the yellow wires passes on the left side of the bike from the regulator to the engine. There are also connectors along the way that gets corroded.
Good luck and Thank you for using FixYa. Happy Holidays.
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