Battery drains no headlight or engine fan - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

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post #1 of 5 (permalink) Old 07-16-2008, 11:58 AM Thread Starter
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Battery drains no headlight or engine fan

I have a VN750, year 2000, after driving on the highway for about 40 minutes my bike died, I tried to restart but the battery was dead. When I got home I replaced the battery with a new one and everything was fine. The problem came back a few days later this time I checked the voltage to make sure the battery was charging thatís when I notice that my headlight doesnít come on nor does the engine fan. Iím wondering if the problem is the junction box or if theirs a bigger electrical problem. The main problem is that the battery gets drained; the headlight doesnít come on unless you tap the starter button and the engine fan doesnít kick on when the engine gets hot. The reason that Iím looking at the junction box is because the headlight and engine fan relay is part of it. Has anyone had this problem before?
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post #2 of 5 (permalink) Old 07-16-2008, 03:06 PM
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If you do a search I think you will be surprised at the volume of info on this problem! Having gone through it myself, I can tell you that you can have one to many problems going on. The first thing you should do is test the condition of the charging system. Here are the links for the procedure:

After you determine the issue(s), if any, with the charging system, you can move on to the junction box relays. Check the Vulcan Verses, there is a ton of good info in there in this area. BTW, I assume that you replaced the battery with a MF. Do a search on R/R or RR, and stator. Just make sure you set aside a chunk of time to read through it all!

One question for you, you mentioned that you checked the voltage at the battery, what was it? What is it with the bike running, at idle, and at 5000 RPM? This will be the first stop on the diagnostic tour!

There are a lot of knowledgeable folks here that can help you through this issue. Good luck!

Wayne, NJ
1989 VN750-A5
VROC #27781
-Replaced/Fused Stator & Replaced/Relocated R/R (15K mi.)
-MF Battery
-Splines Lubed
-Stebel Nautilus Horn
-AutoMeter 2" VOM
-Silverstar Headlight
-Refinished Gauge Rings and Mirrors(Flat Black)
-Refinished Swingarm/Lubed Pivots
-K&S Turn Signals Clear Cover/Amber Bulb
-Kenda Kruz 110/90-19 front 170/80-15 rear
-Clear Alternatives LED tail light
-Plexifairing III
-Willie & Max Saddlebags and SissyBar Bag
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post #3 of 5 (permalink) Old 07-16-2008, 05:08 PM
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don't know if this helps. I had a similar problem on my VN750. Mine was a 1993 bike. The regulator rectifier was mounted on the bottom of the battery box and all the rain would be flung up at it. The regulator voltage sense wire corroded against the earth and caused BIG problems. Not sure if the regulator is mounted in the same place on your bike but have a look.
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post #4 of 5 (permalink) Old 07-21-2008, 09:53 PM Thread Starter
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Thanks for all the tips, after doing some testing over the weekend it looks like my R/R and stator are shot. None of the readings on the R/R were correct and all of the yellow stator wires had continuity readings to ground but did show the correct readings when checking the resistance between the wires. I understand replacing the stator is no walk in the park, do you of any tips or tricks on replacing the stator without completely remove the engine?
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post #5 of 5 (permalink) Old 07-21-2008, 10:01 PM
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There is a tilt method but since the engine is mostly out anyway, you might as well pull it and work on it on a bench. The hardest part is maneuvering it out and back into the frame with the air box in the way.
Remember to remove the front bevel gear before you take the engine out and to replace it after the engine is back in or you will invent new cuss words. Well, more than you will anyway.

Jim W
93 VN 750 "Ursula"
Moved R/R 08Sep06
R/R rewire 17Feb07
New R/R, Installed 14Jun08
New Stator installed 10 Jun08
Maintenance Free Battery 12Jan08
21480 Miles
VROC #8542
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