Hey people. I have a problem with the electrical system. I am thinking my regulator is fried. However, I'd certainly like to hear you opinions. I cross posted this on the yahoo group, but responses were few and far between. I'm hoping that someone will help me here. I'll repost the two posts that I put on the Yahoo group. Oh the prize will be a couple of post cards from Colorado. Its the best I can do, though it won't be enough to repay any help I get.
The first message:
Hey, I replaced the stator about 1,500 miles ago, and replaced the
regulator at the same time. Since then, I've had no problems.
Yesterday, I was on the highway, going about 70 MPH when the bike
The coolant guage was about midway, oil was checked before I left
and I also checked it after the bike stopped, it was still good.
Nothing else seemed amiss.
What occured was while riding down the highway, I was in 5th gear,
probably going about 67 mph. I increased the throttle slightly to
get back up to 70 mph. Suddenly, the bike lost power to the engine.
The headlight indicator started flashing like crazy, and then high
beam indicator went on. The tach would drop to zero and then shoot
back up to around 5,000 or what it would seem to be correct about
the same time the headlight indicator would flash on.
I pulled over, and stopped the bike. At this point, all indicator
lights went out. I first checked for leaking but nothing was unusal.
Oil was still good, coolant good. I didn't have my multimeter, but I
figured the regulator had probably malfunctioned, and the battery
had died. (just a guess, I don't know that the deal was.) I made the
call to the towing service, and while waited, I started poking
around the wiring some more. I pushed on all of the connectors in
the plastic plug that connects the regulator, and then tried the
key. To my joy, the oil light came on. It had been about 15 minutes
since the bike stopped working. I shifted to neutral, and hit the
starter. It made several clicks but the battery apparently wasn't
enough to start it.
I had the tow driver jump me instead. The bike fired right up. The
meter on his jump pack showed a strong charge. I continued, got off
the highway after a mile or so, and then entered Denver traffic. Red
lights, etc. I kept the throttle about 3,000 or so whenever possible
to keep the battering charging. After about a mile, I let the bike
go back to its normal idle speed. Suddenly, while stopped at a
light, the headlight flasher began going crazy again, the high beam
came on, the tach went to zero and the motor all but died. I figured
I should kill the bike now, figuring that I would find a loose wire,
fix it, and be able to restart the bike.
Instead, I found that several of the wires had their insulation
melted. I'm not sure if the wires were shorting out though. The
regulator was hotter than a baked potato.
No fuses were blown, nothing else seemed amiss. However, the heat
had discolored the spade connectors inside the plug. My Regulator is
mounted on the fuse box cover, behind the left side panel. It was
still secured and couldn't be moved when I tried it. The zip ties
holding it to the fuse box were not melted though, so I think the
wires were hot from the electrical current rather than the motor,
which was well in its normal temp range according to the coolant
gauge. The brown wire had about burned through. Basically, the wires
seemed to have all broken, and it was held on by just a peice of
insulation. This was in the plug though, so it wouldnt be able to be
moved back and forth to break it.
I was unable to do much of anything to the bike while stopped the
second time and it was towed about 70 miles (yeah, it cost a lot.)
Once back, I turned the key again, and the oil light came on very
faintly. I assumed the battery had died again, but I left the bike
Today, I checked the battery. 13.1 volts. I checked the regulator. I
set the ohms meter to the 100K scale. All readings were OL
Sorry about this long message, but I wanted to give out all
information that I hope might give you guys an idea of what went
wrong, and what should I do to fix it. This is really depressing.
Follow up message, correction attempts so far:
Hey good people.
I posted a few days ago with my problem. To sum up, I was riding
down the highway and suddenly the headlight warning light started
flashing, the high beam went on, the tachometer died and so did the
The brown regulator wire was completely burned apart, and two other
regulator wires had melted insulation. No fuses were blown.
I got a couple of recomendations, like check the ignition switch,
This is what I have done so far. The battery was fully charged, so
the charging system was likely functioning up to the electrical
I spliced all of the regulator wires together rather than rely on
the warped plug. Currently just temporary, to see whats wrong.
Nuetral and oil lights failed to come on.
Checked ignition switch. FYI, there are 7 wires coming from the
ignition assembly. 5 are in a plastic plug. The other two use
singular bullet connectors. The bullet connector insulation was
melted and burned. These wires are normally connected when the key
is on, so I don't think this would have created a short circut.
Contacts were dirty. Cleaned contacts and tested. All checked out.
hooked switch back up. Neutral and Oil lights came on once, and not
at other key turns. However, the lights may have been so dim that I
didn't see them. (See below) Starter button failed to work on the
time the lights came on.
Disconnected switch. Hard wired all wires together as per wiring
diagrams in Clymers. Essentually hard wired the circuits closed.
Reconnected ground wire to battery. Sometimes when I did this, the
lights would stay off, sometimes they would come on, but most of the
time, the nuetral and oil lights would glow so faintly as to appear
off, and then gradually become brighter until they reached full
strength. No matter, the starter switch still wouldn't turn. Engine
cut off switch was in the "Run" position.
So, does anyone want to take a shot at what the problem might be? If
you solve the problem, I'll send you a post card or two from
Colorado. Small prize I know, but after the tow, thats all I can