All fuses must test and be good, including the ones not in the fuse box. The stator has AC voltage out to the regulator, so you are looking for the phase wires from stator to rectifier, isolate them(disconnect them) and read AC volts from these wires(not to ground but to each other) there are 3 different combinations so write down what they are.you need three sets of numbers around 50 Volts AC with the rpms aroung 1500. if you dont get about the same on each of these you are probably looking at replacing the stator.the wires in the stator sometimes loose their protective coating and then develope too much resistance to output enough power to keep your battery full.(try disconnect all ubnessesary add ons) The wires from stator to rectifier often get hot and melt if not kept clean inside the connectors.(look fot wires that have been hot) Reconnect any that have damage.
SOURCE: charging system problem
mattica,
it is very important to check and verify the AC voltage from the stator output. I don't know what your specific spec is off-hand. you can do this with a multi-meter at the ouput plug from the stator where it connects to the voltage regulator. A BAD stator will ruin a new voltage regulator until it is replaced. I just went through the same exact thing.
SOURCE: Alternator not charging battery on getting 11.5
I had the same problem with my 900 that I just bought, the regulator was fried, so the local kaw shop replaced it with a new one off internet, then it promptly fried the new one, upon further investigation the rotor/armature was reading 1 ohm resistance, supposed toread 4/7 i think anyway, had to have alternater rebuilt , cost 370.00 , works fine now.
SOURCE: Replace regulator/rectifier with a different brand?
Not always necessary to change the regulator/rectifier. Check all connections to make sure they are clean, use a good contact cleaner and finish off with dielectric grease on your electrical connections.
When some bikes get a few years on them the connections get dirty. Check to see if there are any burned or discolored wires anywhere around the regulator. The FIX on some bikes is to cut the connector completely out and solder the wires together and either seal them with heat shrink of a good electrical tape. Loose or bad connections get hot. As long as the regulator and rectifier are working there is no need to replace them if the connections are good.
Ride Safely, Ed
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