Charging system on a 96 Cbr900RR

[gunslinger74]

Having issues with my CBR, went to ride it about a week ago and started having issues with starting. I had issues 2 years ago, found that the regulator was melted and replaced that and the wiring. Fixed the problem until now. I decided to check the regulator again, found a wire frayed and corroded. Cut the bad part out, but now, with a voltmeter, it isn't charging the battery. Jumped the bike to get it started, checked the battery, and only getting 11.03 or so on the meter. Guessing the stator has gone bad now.

Not too good with electrical stuff, or working on the bike too much, just looking for a recommendation for a local small shop in the Reidsville area. I know there is a Honda dealership in Greensboro, but looking for someplace a little less expensive. New to the area, so don't know too much around here yet. Thanks, Jim

[mikek]

charge the battery first, check voltage with NO load, start bike and check voltage with motor running. you should see 13-14 volts at the battery terminals. Ricks Motorcycle Electrics sells alternator windings if you need replacement.
http://ricksmotorsportelectrics.com/...5DQlI5MDBSUg==
Good Luck

[gunslinger74]

Thanks. Charged the battery. Under no load I had 12.4. Started the bike, volts were around 12.2-12.3. The volts would go up a little under revving to 3-4k rpms.

There are 5 wires at the regulator, 3 yellow, 1 red, 1 green. Two of the yellow wires where I spliced the new regulator plug in are getting hot to touch. So, still lost here.

[Desmo Demon]

If you unplug the regulator, you can fire the bike up and check the AC voltage of the stator through the plug. You can also conduct a continuity check on the leads to make sure the stator is not grounded. You'll have to check for information on which wires to check for your bike, though.

Excess heat through the wires or the plug is often from an overcharging or arcing of the voltage (increased amperage). I am guessing an arcing or short from the stator, since you do not see a higher-than-battery-voltage until higher RPMs. The higher RPM producing more AC voltage, which may be required to arc across the connector contacts to finally get a charge tot he battery.

I once had the insulation from a stator wire wear through and had the wire grounding on the frame of the bike. This caused the battery to not charge and if not found soon enough, I could have fried the stator. Check all the wiring of your charging system to make sure you have no grounding issues and check the plug to make sure it is not showing signs of overheating (a sign of arcing across the connector).

Wish you luck!

Edit - You stated that you spliced in a regulator plug. Lightly tug apart the wires to make sure you didn't have a "cold solder" and the wires pulled apart over time. I had this issue with a repair on a repair on a burnt wire on an ignition coil. It looked like it was still connected, but the solder joint came apart and the bike died.

[gunslinger74]

Well, I took it to a local shop here. Gave up looking for the electrical gremlins. The regulator took a crap on me, and my stator was on it's way out. I think one of the wires pulled apart to the regulator and fried it. Replaced that, and the stator and everything seems to be fine now. They soldered they wires also. Here's hoping to no more electrical issues.