Electrical guys I need help

[roboto65]

Ok so I get on the bike this morning and go to start the bike and will not start. So OK push start won,t do that nada so we jump start it runs but then dies if you don,t keep the revs up.. So got it started and got to the gate to leave for home and BAM dead again had to stop to push the button to open the gate!!! Ok so park the bike and run to Wally world for a battery got one put it on varoom starts right up!!!

Get about a mile or so from the house starts sputtering and have to keep the revs up again but made it to the house where it promptly DIES
!!!

So I start trouble shoot and trying to charge the battery which the charger says it is no good brand new and I KILLED it ....

So I start tearing things apart looking for some thing found one thing one of the yellow wires coming off the regulator/rectifer had been crushed and was bare the other wire seem to have gotten hot because they were kinda but not to bad stuck together. Now mind you this is the wire coming from the regulator I guess it is the input from the altenator best I can tell.. I do know that I got it running for a minute and the battery was showing 11 volts and it started but I put the voltmeter on the battery terms and showed no charging going on..., Now my question is does it go thru the reglulator/ rectifier then to the battery form the Altenator or what... This my main mode of transport and had to use the wifes truck to get to work !!!!  HELPPPPPPPPPPPPPPPPPPPPPPPPPPPP  If it is the regulator does anyone have one that is handy so I could rule it out or make sure thats it !!!!!!!

[MagnaDaddy]

I had my main relay (starter relay) go a few months back and it acted much the same.  turned out the relay was totally fried but there's a guy on ebay who sells them for around $30.   Not 100% sure his stuff fits 3rd gen.

[Sledge Hammer]

Now my question is does it go thru the reglulator/ rectifier then to the battery form the Altenator or what... This my main mode of transport and had to use the wifes truck to get to work !!!!  HELPPPPPPPPPPPPPPPPPPPPPPPPPPPP  If it is the regulator does anyone have one that is handy so I could rule it out or make sure thats it !!!!!!!

Allen,

All output from the alternator goes through the rectifier. The battery charges from the rectifier through the red/white wires coming off the rectifier.

With the battery disconnected and removed (so you don't fry your multi-meter), how much resistance do you measure from the positive battery cable lug to the output terminals of the regulator? A broken wire or bad/corroded fuse connection (I assume you have verified the 30A fuse is OK) would certainly prevent proper charging but could still allow starting through the relay, which is a separate path.

Mike

P.S. I feel your pain. My wife's truck just lost its alternator, and after throughly draining the battery, I'm sure I'll be buying a new battery right after replacing the alternator. Lead acid batteries do not like being fully discharged...

[Sledge Hammer]

I had to find my real manual instead of the PDF copy to be able to read the lettering, but yes, the wires from the alternator to the rectifier are the yellow ones. If they got shorted to the frame, that would definitely overload your alternator and starve the rectifier (and thus the battery). If the wires got shorted to each other, at least two of the phases of the alternator got shorted (that could definitely get the wires hot). You'd be revving high sure enough to keep the engine going. Wouldn't be doing the alternator any favors, either.

There is another possibility in that section. If the damaged insulation is close to a connector, that could mean a corroded or mechanically weak connection has developed high resistance and is heating up under the current. A friend of mine recently had that problem with his old Kz650, and, yes, it brought his ride to work to an abrupt halt. He cleaned all the connectors carefully and voila! problem solved.

[Magnum Magna]

P.S. I feel your pain. My wife's truck just lost its alternator, and after throughly draining the battery, I'm sure I'll be buying a new battery right after replacing the alternator. Lead acid batteries do not like being fully discharged...

Last week I thought the alternator went out on the wife's vehicle.  It turned out to be the fuse-able-link opened.  For the uninformed like me that learned the hard way.  In the wire between the alternator and battery is a wire that is a weak link in the wire to act like a fuse.  The alternator can put out over 100 Amps at peak output.  I had the transmission replace and suspect they wired the starter wrong or pinched a wire and opened the fuse-able-link.  But that is only a suspicions of what happened.  I am still looking for what caused the failure.

So check all your fuses and connection.

[roboto65]

YEAHHHHHHHHHHHHHHHHHHHHHHHHH Thanks to a great MOOTSter, Jerry Turner, for coming thru with a regulator and that fixed THAT! Thanks to Jerry my transportation is running again !!!!!!!!!!!! I guess a cut wire means something