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Post by goandy on Aug 24, 2012 6:20:31 GMT -5
When I bought my bike it had toasty wires and connector to the rectifier. I replaced the plug in case it was just a crusty old plug which had burnt out, but today I took the rectifier out to test it. I pulled it apart and tested each diode either way, and got varying values from 300KOhms up to 1.8MOhms. There was nothing even getting close to short circuit one way- I tested using both the diode testing setting on my DMM and also just plain ohms setting. I'm thinking that the rectifier is toast- it certainly looks like it's been hot and nasty- or have I missed something?   |
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Post by jm0406 on Aug 24, 2012 10:20:27 GMT -5
Wow, I've seen better looking thing pulled from the ocean bottom. I understand that was a weak spot in the electrical system. Jess at RR has an updated unit that he sells. Ready to plug in.
Jeff
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Post by re5martin on Aug 24, 2012 11:38:00 GMT -5
hi andy, i had this problem too , replaced the rectifier with one from RR and also replaced the regulator all now is cool . martin
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Post by goandy on Aug 25, 2012 0:16:16 GMT -5
Yes, I'm thinking of using an all in one rec/reg unit. Replace the whole lot with modern electronics. I'm not going for any concours points on my bike!
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gerryggg
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Post by gerryggg on Aug 25, 2012 12:14:51 GMT -5
If you're testing with a digital meter, you'll get crazy readings on the ohm scale, you'll have to use the diode scale. Melted wires that that are indicative of a really high charge rate for a long time. They can be caused by running the unit with a low or bad battery as well as a bad diode. They can also be caused by failure of a stator coil. The good coils try to carry the load of the failed coil and overheat. Make sure you test the entire system, not just the rectifier.
As far as going for an "all-in-one" unit, I haven't found them to be any more durable than the older separate units, in fact, often they are less reliable as the heat from the rectifier can affect the regulator. They are also very sensitive to resistance in the connections to the battery and ground. High resistance in these circuits will make them over regulate. On an older bike the the RE this might very well be a significant issue unless you replace all the wiring.
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ap951
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Post by ap951 on Aug 25, 2012 14:21:10 GMT -5
thank you for sharing your knowledge Gerryggg
you just taught me something I did not know
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gerryggg
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Post by gerryggg on Aug 25, 2012 14:55:50 GMT -5
thank you for sharing your knowledge Gerryggg you just taught me something I did not know Glad to help. Diodes test fine on the ohm scale of an analog meter but don't play nice with most digital meters unless you use the diode scale. As far as the melted wires, after 15 years as a service rep for American Suzuki and 8 years teaching the Suzuki elective at Motorcycle Mechanics Institute in Orlando, I've managed to absorb a little experience with charging systems.  |
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Post by Jess on Aug 26, 2012 11:08:14 GMT -5
The rectifier was woefully inadequate from the factory. In truth they are a disaster waiting to happen.
If the bike was being produced today, it would most likely get a recall for the rectifier.
Stators very rarely fail. I have only ever seen a handful...
Regulators are fairly robust, but are weakened by adverse conditions. (bike storage problems).
As a safety matter... We recommend replacement of a rectifier on any bike that will be used regularly. If you have a garage queen... not really a need.
Just my 2 cents,
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gerryggg
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Post by gerryggg on Aug 26, 2012 22:06:17 GMT -5
The rectifier was woefully inadequate from the factory. In truth they are a disaster waiting to happen. If the bike was being produced today, it would most likely get a recall for the rectifier. Stators very rarely fail. I have only ever seen a handful... Regulators are fairly robust, but are weakened by adverse conditions. (bike storage problems). As a safety matter... We recommend replacement of a rectifier on any bike that will be used regularly. If you have a garage queen... not really a need. Just my 2 cents, Funny, back in the 70s we sold at least 20, maybe 30 units from the dealer I worked for in Florida. At one time we had 6 units in for service at the same time as we were one of the few dealers around that would work on them. I don't recall a single rectifier failure. My experience is most rectifiers fail because people run them with low batteries. Low battery voltage means the charge rate is going to be high and with it heat.On any old motorcycle, the failure rate of charging components is going to be higher than a newer unit. It's a function of age rather than any indication of a design weakness. As far as stator failures, they go hand in hand with rectifier failures. When one goes. the likelihood of the other failing goes up, especially if the first is not caught immediately. Another culprit is starter motors. As they deteriorate, the amperage draw at start up goes up, putting a greater load on the battery and subsequently the charging system. I always check starter draw after replacing a failed charging component. Excess starter draw is still another consequence of an aging electrical system. Age causes among other things, oxidation, oxidation increases resistance. Increased resistance causes increases in current flow. It's a vicious circle when dealing with old motorcycles. After I get mine running I'm seriously considering re-wiring it from scratch myself. Since no one makes a new harness, anything out there will have issues related to aging. |
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Post by goandy on Aug 27, 2012 1:33:46 GMT -5
Thanks for all the input. I've now tested both bikes' stators and rec's. The spare rec is fine as are both field/stator windings. Reg's I'm not sure about- will probably run them and see when I get my motor bolted back together.
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