1992 charging problem - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 12 (permalink) Old 05-06-2012, 12:03 AM Thread Starter
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1992 charging problem

Hi everybody...I'm buster and moved here because sfair on the "vulcan forums" said he thought you guys could help since this is what my bike is (750)...


Had the r/r replaced then did it myself second time and THEN took it to shop...
They said it was likley the same thing again....told them i just replaced it and that i had a wiring harness to put on but no time...should have done it myself...they replaced the reg/rec then said it was STILL heating up (r/r) and told me it was likely a short somewhere..took them the wiring harness (used) and they took over a month and a half ($475 Reg/harness/labor)to fix it...rode ok coming home though different -seemed to have less "get up N
Go" but it seemed smoother and able to wind out more between gears (wierd i know).
So since bringing it home this is first day out...missing as before and i noticed that the "GROUND wire" coming off the reg/rec and bullet to a battery cable and grounded to frame getting VERY hot...to hot to hold in hand...tried grounding to bATTERY AND THAT DID NOT HELP...IROICALLY THE OLD WIREHARNESS HAD A BURNED OUT SLOT WHERE THAT GROUND WIRE GOES INTO THE R/R....stange days indeed !!!
any help is greatly apreciated...
buster
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post #2 of 12 (permalink) Old 05-06-2012, 11:36 AM
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Hi Buster and welcome, have you checked or had the stator checked out to make sure that is ok have you a good AGM battery and I would give all the electrical connections a good clean and grease with dielectric grease.
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post #3 of 12 (permalink) Old 05-06-2012, 12:01 PM Thread Starter
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charging issues

thanks for getting back to me...the stator was checked several times and said to be ok...I just looked at the AGM batts and they range from $40 something to about $90...what would you recomend I use?
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post #4 of 12 (permalink) Old 05-06-2012, 12:19 PM
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Not sure what batteries you get in the states but I see some of the guys get Dekar, or I believe the go to Sears or somewhere. I bought a Motto Batt over here in the UK cost £42 seems good at the moment and there was a good test run on it.
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post #5 of 12 (permalink) Old 05-06-2012, 01:38 PM
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Here is a list of compatible AGM batteries.

I would perform the tests on the stator and R/R yourself. I have seen many threads where mechanics completely missed the mark on our charging system.

Grab a multi-meter and hit up slim's flow-chart here.

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 #6 of 12 (permalink) Old 05-06-2012, 02:38 PM
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Not to still your post but have same issue again. Ran good for a week then no charge at all now. The r/r is new insyalled myself stator test good same reedings as the new one I orderd. Would it be worth rewiring the bike can get new harnes for 230 bucks
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post #7 of 12 (permalink) Old 05-06-2012, 03:07 PM
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Quote:
Originally Posted by TheEDGE View Post
Not to still your post but have same issue again. Ran good for a week then no charge at all now. The r/r is new insyalled myself stator test good same reedings as the new one I orderd. Would it be worth rewiring the bike can get new harnes for 230 bucks
Did you run through the basics like cleaning and verifying all ground connections, etc?

230 for a harness.. ouch!

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 #8 of 12 (permalink) Old 05-06-2012, 04:49 PM
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Take note that according to the manual, replacement of our wire harness requires a full engine pull.. Check AC volts between stator terminals (mark wires A, B, C,; check A-B; A-C; B-C; should read between 50-70ACv @ 3-4k rpms). If stator is good, trace all charging wires for bad connections (rust/corrosion). Make sure to check batt. ground to frame. Bad corroded connections causes the wires to overheat, crack, brittle, splice. Ride safe.

1988 VN750[SIGPIC][/SIGPIC]
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post #9 of 12 (permalink) Old 05-06-2012, 05:15 PM
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I replaced my harness with out pulling the engine.. the only reason for pulling the motor would be because of where the wiring harness is wedged between the frame and rear cylinder. but you can snake it through easy enough.
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post #10 of 12 (permalink) Old 05-06-2012, 07:42 PM
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Yes have been through the basics and found nothing out of the ordinary. Pulled all wires and they looked good no problems. Pluged it all back in and worked fine for a week then hit a pot hole the other day bwith a leaky fork. Then all went to total hell on me checked wires and stator again all shows the same. I did replace the r/r the first time because the stator had been replaces in 2008 but not ther r/r.

I hate electrical work and if doing the wire harness would save me some trouble in the ling run then I don't mind doing it but was hoping to wait.

I'm trying to ride it while I stock up parts so I can customize it saving for the rake kit right now.

Anyways ranting to mutch now any help is aprishiated thanks again

Ride safe
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