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Author Topic: Everyone might want to check this on their bike ...  (Read 808 times)

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Offline Crilly Wizard

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Everyone might want to check this on their bike ...
« on: September 20, 2021, 03:41:37 pm »
The cause of my problems in the "Experienced opinion wanted" thread, ... turns out that the stator cable which joins to the rectifier is routed behind a sharp horizontal bracket about 3 inches from the rectifier.

Over time (35,000 miles), the vibration had cut one of the 3 wires within the triple bus causing stator growl, and as it cut through the second wire, there must have been a high voltage short from ground to positive battery terminal which burnt the red plastic battery terminal cover, before flattening the battery. The bike was still charging and running with one of the wires cut, which I didn't know about (but the cut wire end was old and corroded, so had been like that for some time). Two cut wires stopped the charging completely, and ran the battery flat.

This looks like it could happen to all bolts over time, due to the wire routing tight against the sharp bracket lip, and it might be a good idea to check yours before similar problems occur, and maybe cushion the bracket.

Other wires behind that bracket include the side stand switch cable, and rectifier to battery cable, which may even be connected to the main loom, so this could have been even worse.
I diode tested the rectifier and it is still fine. Stator is still fine, surprisingly.

The engine management light has stayed on after fixing these wires, with the charging system working fine again.
Does anyone know how to get this light off? (The bike runs well again).



Offline E

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Re: Everyone might want to check this on their bike ...
« Reply #1 on: September 21, 2021, 11:08:34 am »
Ugh, wish you would have Attached a Photo - of exactly what SHARP Bracket  you are referring to ?
Need to removed the Seat to see this bracket near battery ? , elsewhere ?
E - 1st John 4:10

Offline srinath

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Re: Everyone might want to check this on their bike ...
« Reply #2 on: September 21, 2021, 11:49:22 am »
He said by the regulator/rectifier - think that's down on the frame right in front of the swingarm ? Or is it on the swingarm ?
Cool.
Srinath.

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Offline Crilly Wizard

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Re: Everyone might want to check this on their bike ...
« Reply #3 on: September 21, 2021, 01:31:10 pm »
Nothing needs removed.
Itís in front of back wheel, just above the rectifier. Horizontal bracket which is part of the rectifier mount. The wires are routed behind this, but as the stator wire is at the top, it bends tight to the sharp edge of the bracket. The stator connector is the grey one.

Offline Crilly Wizard

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Re: Everyone might want to check this on their bike ...
« Reply #4 on: September 21, 2021, 01:51:05 pm »
It doesnít photo well, but the horizontal bracket is highlighted, with my fixed triple wire now in front, and sponge behind to cushion the other wires

Offline Sattes

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Re: Everyone might want to check this on their bike ...
« Reply #5 on: September 21, 2021, 07:29:55 pm »
Thanks for the heads up. 👍

Offline ShakerNorm

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Re: Everyone might want to check this on their bike ...
« Reply #6 on: September 26, 2021, 06:51:11 pm »
Good Catch, WIZ!
I'll pin it so everybody catches it.
NOBODY hates winter more than a Canadian Biker!