FINALLY Repaired- Embarrassed
Hello to all,
I am the guy who bobbed my 2003 750 and has been fighting with her the whole time. I purchased a bike with a known bad stator...but the price was right for a bike in very good condition. I read about the tuxedo modification, and without hesitation, I gave it a shot. However, I used a cheap replacement from EBay...first of many mistakes with my nightmare. The cheap stator came apart and ruined my magneto...which ended up requiring an engine pull anyway. Here is what I ended up doing to the bike over the next few weeks (or months) to the electrical system.
1. Tuxedo Modification
2. New Caltric Stator and regulator (big mistake)
3. New Shorai Battery
4. LED Turn signals
4. New Headlight
5. Bobber Tailight
6. Switched Cooling fan
7. Engine pull to change magneto
8. NEW Stator from Ricks Motorsports (in case the previous stator was grounding with heat)
9. New Mosfitt Voltage Regulator
10 New relocated ignition switch
11. Blue wire modification
12. Two wire modification
Still, the bike would not charge. She would run great on a fresh charge, but suddenly it would discharge the battery and kill the bike. Even blew the 30 amp fuse one time. Was driving me crazy. As suggested by someone here on this forum...I went back and checked every single wire connection I made. Checked for cold solder joints...checked for failing heat shrinks. Checked my grounds over and over. I tested the stator...checked out fine...but I changed it again in case it was grounding out under extreme heat. I was about ready to drive my bike into the Indian River out of frustration.
Yesterday, I added oil to the bike (after the last stator change) Then, I grabbed the battery and dropped her into place under the seat. Suddenly, I saw it....plain as day. The positive battery terminal was almost touching one of the bolt lugs on the frame. Then I shook the battery...and it did touch creating a spark. If I would have taken the time to install the battery terminal straight to begin with, and actually made sure the red rubber terminal cover was pushed into place correctly, it never would have happened. The battery was actually vibrating when running, then, grounding out to the frame and killing the battery suddenly. With simple adjustments, the bike fired right up and rode perfectly for several hours.
Moral of this story is: Never assume anything. Don't be stupid like me and overlook something as simple as this. Obviously the bike needed a new stator and regulator anyway, but I could have saved myself a lot of headaches along the repair process. I am ashamed of myself. I am supposed to be a mechanic.
My son is due home from overseas in 30 days after this latest deployment, and I will be giving this bike to him He has spent the past several years protecting me here in the US, so giving him the bike is the least I can do for him. #GoArmy #FightingMan