I don't understand the tests... - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

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post #1 of 17 (permalink) Old 07-12-2010, 01:13 PM Thread Starter
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I don't understand the tests...

After 18 months 100% reliability my 750 began thumbing its nose at me Friday evening. I noticed as I was riding home the analog voltmeter was suddenly stuck around 12v, dropping to almost 10v with fan, brakes, directionals and what not. I made it home and parked it, tired and stressed from the day, knowing I wouldn't be able to get to it until Saturday afternoon.

I began by dismantling everything and checking all the connections I could and by accident learned if the headlight is disconnected the system appeared to charge correctly (both via the voltmeter and battery). But once re-connected it didn't - sometimes the light wouldn't even come on! (note: AGM battery tests healthy reading 12.8v with no load and at idle, without headlight shows charging to around 14v - not so with headlight connected)

After physical wiring/fuse checks and tests with the cheap digital multimeter I don't really know how to use, searching this site for answers and guidance with an unwillingness to open up any part of the engine, I ended up with no understandable or useful results and not knowing what to do. Hours after I began, sweat soaked, filthy and WAY past frustration, I quit and canceled my trip to the National Rally to avoid my being stranded. (none of this includes the neat little oil leak from the shifter I discovered - I won't bother with the expletives, they'll just turn into ****** **** **** ****!!!!!)

I'm sooooo disappointed and feel like an idiot loser. I've never pretended I was any kind of mechanic, and while I've succeed with other maintenance just fine thanks to this site and its members, I just can't do it... not anymore. I'm all alone here, and sooner or later I'll take it in and let professionals set it right again. I'm too pissed off to even look at it right now.

Michael
2002 Nomad 1500
VROC #29972

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Last edited by msh1156; 07-12-2010 at 01:16 PM.
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post #2 of 17 (permalink) Old 07-12-2010, 02:28 PM
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Check your stator wires and connection (three wires that terminate near the batt under the left side cover). My wires are stiff from overheating and my connectors were corroded - I cleaned the connections, greased w/synthetic dielectric grease, that fixed my charging problems.

DT

95 VN750 (eBay)31k+
GL1100 front fender
OEM engine guard
OEM high back rest
'V-Twin' HWY pegs
Black 750 Spectre handlebars
SunPro Volt Meter (Amazon)
Maier bug shield (JCW)
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WalMart Saddle Bags
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post #3 of 17 (permalink) Old 07-12-2010, 05:39 PM
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You may have a grounded wire in the headlight. Check your wiring in the headlight area and the wires leading to the headlight. Sound like a grounding problem, it won't drain the battery because no power goes to the headlight until you start the bike.

2004 25,500 miles
Led tail light enhancement
Homemade floor boards
Headlight modulator
Extra heat sink on R+R
R+R relocation
Homemade driver's backrest
Fused Stator
Mcct conversion-cost 4.50
Ride-on in tires
crash bar with home made hyway pegs
iridium plugs
home made fork wind deflectors
coil pickups adjusted.
Kenda kruz tires 110/90 170/80
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post #4 of 17 (permalink) Old 07-12-2010, 06:11 PM
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msh I hate to here you're not going to make it. We got to Robbinsville around 3 this afternoon. We were all soaked but we made it. Hope you get it figured out, maybe in time to join us.

Mom, I'm not wearing my helmet only for the purpose of taking this picture and
the background was digitally blurred to make it look like I'm going really fast.
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post #5 of 17 (permalink) Old 07-12-2010, 08:57 PM
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What size headlight do you have. I had the same problem with the headlight after I put in an aftermarket 80/100w headlight. What happened was the light was so hot that it started melting the headlight plug-in and started shorting out.

On a side note...msh I noticed you on the VRA site. Baldy here from the Maine chapter. I hope you get the bike fixed so you can make the rally. I wish I could go but not enough $$ to make it.

01' VN750
Jardine cross over exaust
Kyriakin grips and foot pegs
Modified seat and backrest
Windshield
Luggage rack
Crash bar with Kyriakin pegs and extensions
Kumho 758 165/80-15 CT rear Dunlop 404 110/90-19 front
Coastered and air/fuel screws at 2.5 turns
Spline lube

93' VN750 getting TLC
Decals and mirrors
Coastered and air/fuel screws at 2.5 turns
ACCTs to MCCTs
Degoated with Harley mufflers
Duro 110-90-19 front 150-90-15 rear
Pick-up coils at .020
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post #6 of 17 (permalink) Old 07-12-2010, 10:27 PM
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My alternator leads were also loose and heating up, not to mention a bad battery. If you have loose connections you will lose voltage.
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post #7 of 17 (permalink) Old 07-13-2010, 07:41 AM
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Garage
Also check the Reserve Light Unit
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post #8 of 17 (permalink) Old 07-13-2010, 07:42 AM
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Quote:
Originally Posted by dirtrack650 View Post
Check your stator wires and connection (three wires that terminate near the batt under the left side cover). My wires are stiff from overheating and my connectors were corroded - I cleaned the connections, greased w/synthetic dielectric grease, that fixed my charging problems.

DT
Msh, I've found that the majority of electical issues are simple contact connection problems. Clean the corrosion or tarnish off your contacts, put a little dieletric grease on them to protect and improve the connection, and make sure they're tightly connected. Do this to the battery itself, to the stator as DT mentioned, and to your headlamp connections as well. Make sure no wires get pinched when you re-connect your headlight bucket. Perhaps that's all it is...

Rubyrick

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Splines lubed when tires installed at 10,650 miles
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post #9 of 17 (permalink) Old 07-13-2010, 10:11 AM
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Quote:
Originally Posted by rubyrick View Post
Msh, I've found that the majority of electical issues are simple contact connection problems. Clean the corrosion or tarnish off your contacts, put a little dieletric grease on them to protect and improve the connection, and make sure they're tightly connected. Do this to the battery itself, to the stator as DT mentioned, and to your headlamp connections as well. Make sure no wires get pinched when you re-connect your headlight bucket. Perhaps that's all it is...
Aslo spray WD-40 on all wire connections after cleaning them and applying dielectric grease. It keeps corosion away, keeps the wires from drying and cracking, and sheds water

01' VN750
Jardine cross over exaust
Kyriakin grips and foot pegs
Modified seat and backrest
Windshield
Luggage rack
Crash bar with Kyriakin pegs and extensions
Kumho 758 165/80-15 CT rear Dunlop 404 110/90-19 front
Coastered and air/fuel screws at 2.5 turns
Spline lube

93' VN750 getting TLC
Decals and mirrors
Coastered and air/fuel screws at 2.5 turns
ACCTs to MCCTs
Degoated with Harley mufflers
Duro 110-90-19 front 150-90-15 rear
Pick-up coils at .020
Spline lube
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post #10 of 17 (permalink) Old 07-13-2010, 04:04 PM Thread Starter
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Slim - I am grateful for your reply, but after reading my rant do you think I know what the Reserve Lighting Unit is????

I went and bought an analog multimeter. Here are the readings from the RR.
(set to x100 which I could not do before)
+ B to M = inf
+ B to G = 3.75 should be between .4 and 2 *** fail?
+ B to A1,2,3 = .6 (top limit??)
+ M to B = inf
+ M to G = 3
+ M to A1,2,3 = inf
+ G to B = inf
+ G to M = inf
+ G to A1,2,3 = inf
+ A1,2,3 to B = inf
+ A1,2,3 to M = inf
+ A1,2,3 to G = .6 (top limit??)

I will have to return this meter since it won't read x1 ohm for stator tests. Should have checked that. This bike has very clean and strong connections that have been checked, confirmed no pinching/bad connections in the bucket, stock voltage bulb, fuses good, battery very good. If it's not the R/R, then this ride will be sitting a while. I don't have the skills/temperament/buddies it takes to swap a stator on my own, nor to I have a spare 6-7 hundred bucks to pay the pros.

Stealership wants 65 bucks just to test the leads. I await one more set of replies before going there.

Michael
2002 Nomad 1500
VROC #29972

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