electrical problems

[merrow]

I had posted a problem with my bike's charging system a few weeks ago.  The battery was over charging.  I put in a new battery and it was okay for a couple of weeks.  Then the problem started up again.  We purchased a voltmeter and it indicated the bike was puttin out about 18 volts.  So we ordered a voltage rectifier.  It came as we were walking out the door to head out on a trip.  We put it on and loaded the Magna and took off, thinking problem solved.  On the way home, it started overcharging again, we had gone about 350 miles.  We checked connections, put in another battery and made it home, but the bike is now sitting while we figure out what is wrong.  Could the part have been defective, or is there something else causing this?  I would appreciate any ideas.

[TLRam1]

Your issues were just repeated at the wrench session this past weekend.

Someone will chime in as to what was found and or how to check your system. It was on Bob's bike and Len was helping. Appears to be a poor connection if I remember correctly but was eavesdropping so don't put to much weight in that.  You may PM Len A. or Bob for a quicker response.

[trapper]

I would think perhaps that there is a short of some kind, causing an increase in voltage?

[John Luttrell]

Was the voltage rectifier you bought a OEM Honda part?  I remember reading about a batch of bad rectifiers, but can't remember what brand they were.  I'll try to find out which brand it was; I do however remember it was not OEM parts.

[John Luttrell]

Browsing around a few other of the honda forums I found that everyone that had an over charging problem fixed it with a new "Honda" Rectifier.  Those that replaced it with an after market rectifier had to later install a new "Honda" to finally fix the over charging problem.  It seems as though most of the defective after market rectifiers were sold under the Electrasport brand name.

[trapper]

That's great to know, John.  Thanks for checking into that retifier issue

[rjb/AKA Bob Barram]

Well, let me weigh in on this subject. I only know enough on reading a meter to check if there is a good connection but my friend Don (who does know how to operate the meter) and I went through the diagnostic check as outlined in the owners manual and found that the voltage regulator/rectifier was not working correctly. I have ordered a new one from dennis kirk and hope I do not run into the oem  non oem problem.
Like Terry said, I  had all the same symptons.
Bob

[rjb/AKA Bob Barram]

It looks like the new regulator/rectifier from DennisKirk.com solved the problem. I replaced the unit and my voltage meter never went above 14.5! I took it for a ride watching the meter and looked like all was working correctly. I connected my speakers, accent lights (leds) and heated gloves and took it for another ride and everything still looks good. Needless to say I am a happy biker again!!
I learned a few more things on removing/replacing the regulator/rectifier that the manual does not bother to tell you about.

When removing the regulator/rectifier (aka RR in this note)
1. remove the seat
2. disconnect the 2 cables to the rear of the battery going to the RR
3. get a 10mm socket that has a bolt like head on it that you can attach a small wrench to and masking tape the wrench to the socket. Make sure the socket has a deep nut slot so the bolt does not keep the socket from gripping the nut. If you cannot find a bolt like headed socket you can use a longer socket and a small vise grips. Attach or tape the two together and patiently use it to loosen the nuts holding the RR to the battery case. (left to loosen, right to tighten) When you get the nut loosened with the wrench/grips you should be able to finish the job with your fingers and the socket.
4. run the new RR wires back up between the battery case and the rear fender. A hanger with a small hook on one end helps with this part. One thing you will find that is different with the denniskirk RR is the length of the cables are longer, which is good. But the bad part of the denniskirk RR is that the connectors are slightly too big to fit in the holders for them. But it allows you to hook them up easier.
5. Put the RR in the bolts sticking out of the bottom of the battery case and start the nuts with your fingers and socket. Once started finish with your homemade angled socket.
6. tuck away the extra cabling from the RR behind the battery box so it does not rub the bottom of the seat.
7. Now you are a satisfied Magna owner again!!!! 

[Greg Cothern]

Glad to hear your up and running again Bob! 

[Charles S Otwell]

Ok Bob mine next

[merrow]

We are still working on my rectifier problem.  The one we put in is an electrosport.  The wires were very long, one of the plugs did not have a locking socket on it and it did not fit in the bracket.  After a few hundred miles, the insulation on the wire wore through and the wire frayed which started the problems again.  So now we are negotiating with the company we bought it from.  I will post more as this saga developes.  So if you have the aftermarket rectifier, be careful and check where all that excess wire is.