Battery not charging - no voltage change while reving - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 12 (permalink) Old 11-24-2011, 07:49 PM Thread Starter
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Battery not charging - no voltage change while reving

Well, it looks like my bike is not charging at all. I went to start my bike this morning and had a dead battery. I charged it most of the way and the bike started up fine, but I get no voltage change directly off the battery when I run through the rpms - it stays stable. The battery wasn't super charged and it was holding around 11.7 (tested 12.4 before I started it, wasnt a 100% charge). It would sit at 11.7 during any rpm.

The negative lead off the battery broke off the frame recently and I think this could have fried the R/R or stator when it occurred - as the bike kept running and I did not notice it until it would not start the next time.

I am hoping it is the R/R since there is no voltage change at all when I rev. I would think if the stater was going it would just push some change, but not enough to charge.

I'll test the stator tomorrow, but does anyone have any experience with it not charging at all while reving to give me some direction?

A PO did the tuxedo mod so changing the stator won't be an issue if needs be. I am just not wanting to spend a $100ish on a part - the $40ish R/R seems preferable.

Edit after thought: Maybe I damaged the battery? It's been charging 6 hours and is only reading 12.77 - the battery's manual states @ 1.5A it should take 2-5 hours to fully charge. Also, if I damaged anything I am leaning towards R/R or junction box at this stage. Everything had been charging before, so if a DC ground was lost and damaged something I would think it would be on the DC side, seeing as the stator is AC and directly connects to the R/R (correct?). I'll have to test tomorrow, too late to wake the neighbors and I'd like a fully charged battery. Sigh, I'm getting to do everything at once with this bike!

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350

Last edited by thtanner; 11-24-2011 at 09:27 PM.
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post #2 of 12 (permalink) Old 11-25-2011, 03:54 PM Thread Starter
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Well the battery pretty much refuses to green light my charger, so I am thinking the battery is no-go at this stage. I'll be doing a full check on wiring and voltages with my old (but still good) battery in.

Here's wishing me luck.

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #3 of 12 (permalink) Old 11-25-2011, 04:41 PM
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Having the ground cable come off would not likely have damaged the stator. It will run completely disconnected without damage. I can only hope that whoever did that mod removed the cover before doing all that cutting. Not a good thing to have an engine full of metal dust and shavings.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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post #4 of 12 (permalink) Old 11-25-2011, 06:12 PM Thread Starter
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Well, here's an update.

The R/R is testing bad. The diode test is failing on the third stator input to the 12v. I haven't even gotten to the stator yet since there was a huge visual red flag when I disconnected the R/R.

Connector from the R/R


Connector from the bike


I guess I need a R/R to start with....

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #5 of 12 (permalink) Old 11-25-2011, 11:06 PM
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Yepper, that is fried alright. My '85 Goldwing had 3 of those white plastic connectors between the stator and the R/R. All were badly burned. I cut them out, and soldered all the wires together between the stator and R/R. Both the stator and R/R tested good, and the battery was charging, but the R/R was still running red hot. I was afraid it could go any time, and leave me stranded far from home, so I finally gave up and went with a belt driven car alternator, unfortunately not an option on the Vulcan. The 4 cylinder Goldwing is another bike where you have to pull the engine to get to the stator. The problem with it is the stock R/R lacked anywhere near the capacity to handle the stators output, and there is no known upgrade.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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post #6 of 12 (permalink) Old 11-26-2011, 09:31 PM Thread Starter
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I have a new r/r wiring harness on order to get rid of the nasty stock one that looks like it was assaulted with battery acid at one stage.

A replacement R/R off a '92 Ninja ZX600 was a whopping 16.99 shipped, so here's hoping that it tests good - as it is a compatible part.

I guess waiting for all this gives me time to do all of the fluids, spline lube, and replace both tires.

I am just hoping I don't have to do the stator but if so, no big deal. I'll test that as soon as the new R/R is on. I don't really want to run the bike with the bad one just in case.

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350

Last edited by thtanner; 11-27-2011 at 10:37 PM.
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post #7 of 12 (permalink) Old 11-28-2011, 10:32 AM Thread Starter
1986 VN750
 
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For posterity's sake I am just posting where I got the replacement wiring harness (female - bike side).

I got it here:
http://www.ebay.com/itm/VOLTAGE-REGU...item415fbe0648

It is also available here if the eBay item is no longer available when you need it.
http://www.procycledepot.com/content...S?item=1680804

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
thtanner is offline  
post #8 of 12 (permalink) Old 11-28-2011, 09:31 PM
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Quote:
Originally Posted by thtanner View Post
I have a new r/r wiring harness on order to get rid of the nasty stock one that looks like it was assaulted with battery acid at one stage.

A replacement R/R off a '92 Ninja ZX600 was a whopping 16.99 shipped, so here's hoping that it tests good - as it is a compatible part.

I guess waiting for all this gives me time to do all of the fluids, spline lube, and replace both tires.

I am just hoping I don't have to do the stator but if so, no big deal. I'll test that as soon as the new R/R is on. I don't really want to run the bike with the bad one just in case.

I am pretty sure that I got that stator cover from Rags right before you did... I know hes making you one but I would happily give you this one and get the next one if you need to do your stator. I am in no hurry at all.

Jay

Accomplishments;

Changed Final Drive Fluid
Iridium Plugs

NGK Spark Plug Wires
Bridgestone Spitfire Tires
Maintenance Free Battery
Lubed the Spline
Shaved and Coastered
Under Tank Air Filter
Re-Jetted
Vn900 Seat Mod w/ Honda 1100 Backrest
Rebuilt Petcock
Custom Mirrors
Custom SaddleBags
LED Taillight
Heads Up Voltage Monitor

Upcoming: Change front fork Seals & Oil, install highway pegs & floorboards
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post #9 of 12 (permalink) Old 11-30-2011, 02:20 PM Thread Starter
1986 VN750
 
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That's awfully nice MaDeInSin. I guess we'll see after I put in my replacement R/R.

The R/R just came in but the replacement harness *just* shipped today - horrible! I'm going to go to some auto stores to see if I can find a harness to replace mine *today* as I really don't want to cause issues using a janky harness.

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #10 of 12 (permalink) Old 11-30-2011, 05:13 PM Thread Starter
1986 VN750
 
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...and now we're charging! Up to 14.5v while > 3k rpm.

The cheap Chinese regulator lasted (at most) 30 running hours that the PO bought for $60 on eBay, and it never pushed more than 13.6v. This $17 pulled r/r is immediately pushing good charging volts. Goes to show that sometimes quality matters

Update: I just got back from an hour or so cruise and all is still well in the world. Feels good to be riding again!

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350

Last edited by thtanner; 11-30-2011 at 08:21 PM.
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