Charging system problem

[DC Smith]

I have been using the listserve trying to solve my problem with my charging system.  Someone said a lot of good info is lost forever using the email system, so I thought I would add this on the forum for others that may have the same problem.  That way it is saved.

My charging system is only putting out 13 volts at 3000 rpms.  This does not keep my battery charged.  After a 50 mile ride it takes my battery tender jr.  6-8 hours to charge the battery.  

The first suggestion was to clean connections.  I have cleaned all connection on the battery, starter, and ground with no improvement.  Battery is less that 2 months old and checks out OK.

It has been suggested that it could be the rectifier/regulator which is all in one unit and sells for $110 new at discount houses.   It could also be the stator which list for $350+.

Any new ideas or thoughts?  I hate to start throwing money at the problem, without having some confidence that it will work,  but I may have to.  Very frustrating.

[Greg Cothern]

Dan take your R/R to the dealership they should be able to test it and let you know if it is bad or good.
Then you will know what your next step will be.

[John Luttrell]

http://i2.photobucket.com/albums/y6/johnlutl/chargingsysteminsp.jpg?t=1177546194
http://i2.photobucket.com/albums/y6/johnlutl/regulatorcheck.jpg?t=1177545061
http://i2.photobucket.com/albums/y6/johnlutl/alternator.jpg?t=1177545574

Perform the first part of this check with the battery charged to at least 13 volts and the engine warmed up, but off. The second part is engine running checks.
http://i2.photobucket.com/albums/y6/johnlutl/chargingsysteminspcont.jpg?t=1177546683
http://i2.photobucket.com/albums/y6/johnlutl/unitinspection.jpg?t=1177693338

[DC Smith]

John,

Thanks those were a lot of help.  I went and dug out  my service manual that Greg sent me on disk, and printed chapter 15.  If you could add page 15-8 (I don't know how) to your post, it might really help someone else.

Greg, the dealer wanted me to bring in the bike to test the system and wanted $70, so I tackled it with the help of a friend.  Here's what we found:

1.Resistance on the regulator/rectifier was slightly out of specs.

2.  The test on the alternator/stator showed no resistance between  the     yellow terminals.

I was using a cheapo multimeter but I am thinking it is the stator.  Any ideas? And if it is, is there any way to repair it?

Dan

[John Luttrell]

I would pull the stator and inspect it for any obvious broken connections or broken wires.  They should be able to be repaired by soldering the bad connections back together.  You may be able to take the stator to an automotive electrical/alternator repair shop if you don't feel up to it.