Another failed Electrosport R/R... need some advice. - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 40 (permalink) Old 10-24-2006, 05:24 PM Thread Starter
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Another failed Electrosport R/R... need some advice.

The voltmeter I installed a couple months ago finally came in handy today. I was riding the bike and noticed that the voltmeter was only reading between 12 and 12.5 volts through all engine speeds. Immediately I suspected the R/R.

Some background... I replaced a failed Kawi R/R (presumably the original) back in July. Everything worked fine with the charging system after the replacement. Then I had some more problems a month ago (some of you might recall the 'southern bound' thread)... fried the R/R... replaced it with another Electrosport R/R... everything worked fine.

So today... no charging. The stator is putting out juice... 40-50 V at 3000RPM across all three stator leads. I took the following readings on the R/R (the bracketed numbers are Kawi specs outlined in the manual). 'I' indicates infinity:

B- M+ : I [I]
B- G+ : 6.44 mOhms [I]
B- A1+: 7.24 mOhms [I]
B- A2+: .817 mOhms [I]
B- A3+: .926 mOhms [I]

M- B+ : I [10 kOhms - I]
M- G+ : 34.19 mOhms [10 kOhms - I] ***
M- A1+: I [10 kOhms - I]
M- A2+: I [10 kOhms - I]
M- A3+: I [10 kOhms - I]

G- B+ : I [0.4 - 2 kOhms] ***
G- M+ : I [1 - 5 kOhms] ***
G- A1+: 26.41 mOhms [0.2 - 0.6 kOhms]
G- A2+: 37.22 mOhms [0.2 - 0.6 kOhms]
G- A3+: 29.45 mOhms [0.2 - 0.6 kOhms]

A1- B+ : I [0.2 - 0.6 kOhms] ***
A1- M+ : I [I]
A1- G+ : .791 mOhms [I]
A1- A2+: I [I]
A1- A3+: I [I]

A2- B+ : I [0.2 - 0.6 kOhms] ***
A2- M+ : I [I]
A2- G+ : 4.21 mOhms [I]
A2- A1+: I [I]
A2- A3+: I [I]

A3- B+ : I [0.2 - 0.6 kOhms]
A3- M+ : I [I]
A3- G+ : .812 mOhms [I]
A3- A1+: I [I]
A3- A2+: I [I]

The *** entries seem pretty off to me. I talked to Electrosport tech support and they said they don't know what the resistance readings should be... they told me to do a diode test. The diode test, of course, checked out fine. Still though, I think these resistance readings indicate a problem. There is a one year warranty on the R/R, but I'm guessing they won't replace it since the diode test passes. Any advice on this?

paul
1991 vn750: 'for great justice'
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Last edited by global_recon; 10-25-2006 at 11:10 AM.
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post #2 of 40 (permalink) Old 10-24-2006, 05:36 PM Thread Starter
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Well... talked to Electrosport tech support again. They said if the diode test checks out, there could be a problem with the regulator circuit itself, but the problem would manifest itself by showing too much voltage, not too little. When I brought up the resistance readings again, they told me that the Electrosport R/R readings would not necessarily be in line with what is written in the Kawi manual. I pressed a little for a return, and they agreed... I'm going to ship this R/R back tomorrow and hopefully they'll ship a new one out soon. The two wheels on my bike are the only wheels I have right now... no transportation for a while... ugh.

paul
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post #3 of 40 (permalink) Old 10-24-2006, 05:43 PM
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Paul, sorry to hear that buddy! Hopefully you just got a bad one and the new one will last. Hang in there!

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post #4 of 40 (permalink) Old 10-24-2006, 07:10 PM
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i agree with the rep on the voltage would be too high. have you tried checking the dc voltage with a handheld unit to verify that your onboard Voltmeter is working correctly? also you may wanna check all connections, there may be a loose one somewhere as charging system failures are not impossiable, but are very rare in the cooler weather

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post #5 of 40 (permalink) Old 10-24-2006, 08:41 PM
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I just disected an original Kaw part (Shindengen) as it failed on my 93.

I was shocked at what was inside as far as workmanship, absolutely terrible. I am surprised that it lasted this long.

Interesting circuit, kind of like three dimmer circuits in parallel. They short half of the rectifiers with the thrysitors for periods of time to lower the dc output. Could have done it differently, but it works, justs generates A LOT of heat in the process.

I ordered a new r/r from Rick's in NH. They say they make thier own and are much better quality than the original (that won't be hard to do).

$ 105 delivered, a bit more than the other guys, but hopefully worth it.

Jon
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post #6 of 40 (permalink) Old 10-25-2006, 10:47 AM
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I've read, maybe on the kzrider.com forum, where guys are building their own r/r. Must not be that complicated, not to say that I would be comfortable doing it!

Fergy
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post #7 of 40 (permalink) Old 10-25-2006, 10:52 AM
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Jon... Do you have a link to Rick's?
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post #8 of 40 (permalink) Old 10-25-2006, 10:56 AM
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Quote:
Originally Posted by Mark
Jon... Do you have a link to Rick's?
http://www.ricksmotorsportelectrics.com/index.php

Jon
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post #9 of 40 (permalink) Old 10-26-2006, 12:01 AM
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I have a friend that made his own for his Yamaha xs850 with two rectifiers wired up and output to a volvo/penta regulator ( adjustable ) .... ( Radio Shack for the rectifiers mounted to a Pentium 4 heatsink and about 28.00 for the reg ) works great for him! He also wired it to the same type of plugs as stock so "if" it ever did go out then he'd unplug it and plug it back into the stock R/R !

The one from the KZ forum shows three rectifiers but should work just as good!!

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post #10 of 40 (permalink) Old 10-26-2006, 02:22 AM Thread Starter
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i shipped the suspected bad r/r back to electrosport today and then called them to ask if i could pay to have a new one shipped before they received mine. they did one better and just sent out the new one today. they said they'd only charge my credit card if they didn't receive the old one. so, i have to hand it to electrosport customer service... they came through on this one. i really hope the new r/r fixes the problem.

here's a question... could something else in the electrical chain be causing the r/r to die? the original died back in may after a cross country usa trip... then the replacement died last month (although i suspect the problem i was having with my ignition switch at the time had something to do with it; have since replaced the ignition switch with a new one)... now the second replacement has died.

paul
1991 vn750: 'for great justice'
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follow my rides on twitter: http://www.twitter.com/globalrecon

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