[sutty]

So I thought I would start this to help people find topics and issues that might be caused by a faulty regulator. If people could post any issues they might have had along with the type of bike it was on. There is already a thread pinned about regulators but this is more a quick find guide on issues and solutions. Please keep it on topic and free of non issue/solution posts. In the following format...

Bike
Issue
Solution

I'll start of with two issues on two different bikes.

Bike: Ducati Monster S4r

Issues: Bike would no longer be able to turn over each day even after a hour and a half drive done twice the day before. When checking the voltage given to the Battery I was getting 12.6v with the bike idling and 12.8v with the bike rev'ed. After further inspection I found that the connector for the regulator had started to oxidise and melted. While the bike would run, it had to be jumped to get it running. While the bike was running, it was fine. But once it was switched off there was no longer a charge on the battery.

Solution: I had to cut the oxidised wiring and and add in a new connector. Unable to find a block locally I had to use individual connectors to replace the melted block. I also had to replace the regulator it's self. As it was no longer giving correct voltages. Bike is now giving a steady and good voltage. Battery is charging ok now too.


Bike: Honda CBR250rr®

Issues: Battery would not charge correctly so daily the bike had to be bump started. Tested voltage and it was giving correct volts. Tested again directly after a day of driving and was getting 16-18V while the bike was hot and so was the old regulator. Regulator was over supplying the bike and blowing bulbs.

Solution: Replaced the regulator but the battery was no longer able to charge correctly. Removed the battery and found it had started to bulge around the sides. Replaced the battery and all issues had been resolved.


If people want to start adding to it, there should be a good resource for finding issues and how to fix them.

This post has been edited by sutty: 06 October 2009 - 02:36 PM

[V45]

Regulators give out quite a few amps, the power that melts. Many older bikes, most common being Honda, had an inherent problem with the reg wiring. The connections were not the sturdiest. My way of dealing with this issue is to remove the connections and solder the wires together. The more added options we put on our bikes, heated grips, etc., means more power from the reg. The connectors cannot handle the extra load so overheat. Also the prob stated in original post.
Always connect any extras you put on your bike via a fuse. Never connect directly to the battery. Always use cable which is rated higher than the fuse you are using.....you want the fuse to blow before the connections or the cable ignites.
Hope this also helps.

[KildareMan]

My solutions.

http://roadstercycle...grade%20kit.htm

And if too lazy to use the supplied wiring, or want proper plugs

http://www.easternbe...connectors.html

[bobertsoft]

Hi. I'm new here. Wondering if anyone can give me step by step info how to remove and replace my reg/rec. I'm having the exact same probs described above and pretty sure thats the prob. I'm on a Kawasaki er5. Really appreciate any help you folks can offer. Thanks. Rob.

[Alan]

bobertsoft, on 02 February 2011 - 09:57 AM, said:

Hi. I'm new here. Wondering if anyone can give me step by step info how to remove and replace my reg/rec. I'm having the exact same probs described above and pretty sure thats the prob. I'm on a Kawasaki er5. Really appreciate any help you folks can offer. Thanks. Rob.

Not sure if all bikes are the same, but it should be as easy as disconnect the lead, unbolt old one, replace new one, bolt it on and reconnect lead

See it's your first post, why not introduce yourself Here Oh and welcome to the forum