Join Date: May 2015
Location: Southern Oregon
Charging or Electrical Issues (Scratching my head)
Sorry this turned out so long. Grab a good cup of coffee, tea or a beer before starting this novel.
2002 V-Star 1100 Classic. 28,000 miles
My issue is with the electrical system. Like many others on here, I was out for a ride and the cluster panels went crazy and soon after, the bike died on me with a dead battery. I ran all the ohm tests starting with the battery and when I got to the stator I found my wires and housing were melted. To me it seemed like the housing and wires have been that way for a while because of the dirt, oil and debris that were caked into what was left of the housing itself. So I replaced both the stator and rectifier.Soldered the wires together for best connection. Started the bike and hooked the tester up. While at idol it was reading 13.2 - 13.5 and when I revved it up it hit between 14.2 - 14.9 with one high spike of grater than 15 volts. I took it out for a 10 mile run and when I put it back on the tester it was no longer charging. Took my battery into two places to have it tested and both places told me that the battery is fine under the load test. Out of curiosity I put the old rectifier back on and it was charging again. I was getting 12.3 - 13+ on idol and no more than 14.2 at high revving. I ran it for a good 30 minutes today while checking the volts, and not once did the wires from the stator get hot, nor did it pass 14.2 volts on the test at high rev. I took it out for a 20 mile ride and when I got home - it was no longer charging again.
Also, before I replaced the stator and R/R the first time, I had a spell where the 10 amp fuse for the lights blew as soon as I turned the key to the on position, and in a matter of about 20 minutes I went through 5 fuses. I thought I tracked the issue down to my passing lights switch on the front of the bike. When I touched the switch the passing lights would go out, but no fuses blew when messing with it. I put a new switch to the lights and the fuses stopped blowing. It was at that time I took the bike out and 30 miles later all my problems with the bike started as far as the charging system.
For the life of me I cannot find anything on why the rectifier keeps blowing out other than high spikes in power being delivered to the R/R. I am trying to find out what would send or allow that to happen as the Stator is still good according to the ohm testing on each wire and then to the frame. I thought I read somewhere that a particular DIODE (if bad) would allow for this to happen, but I am not sure. Is there another problem that it could be and I am not thinking?
I would appreciate any help or directions you could possibly point me to. Again, I am sorry this turned out so long, I wanted to cover everything that I have done thus far, but I am sure I missed something..
Today I fired the bike up and checked the charging on it just to see and it was charging again. Before i cranked it over it only had 12.1 volts, I have no parasitic draws from what I can measure with the multimeter. So now I am really at a loss here as to what it could be. It seems when the bike is at operating temps the R/R does not charge.
Any ideas where to go from here? Is there a DIODE I need to be looking at? Will a CDI unit cause this? I am itching to ride, but am afraid to take it more than 20 miles from the house because it may let me down again.
I hope this is the correct place to post this, if not please let me know and I will move it...