I just finished replacing the charging system but it's still not charging think I fukered something up. I FINALLY got to go for a good long rip bar hopping with the boys last night and at the last stop at 2am, dead battery. I pulled the battery and when I jump the bike it runs fine but when I pull a jumper cable off the bike leads it dies instantly. When it's running should I not be able to see voltage at the plug in the block where the voltage regulator plugs in? Cause there is none when it's running.



Any help is greatly appreciated..

 

Go through the sticky at the top of the forum.

 

YES....there should be an AC voltage in that plug. Also get a multimeter and check for a short between either socket and earth (if you get a reading then the Stator is shorted to earth and is buggered) or measure between the two sockets themselves and you should have very very low ohms or a basic short (If its open circuit then the stator is buggered)

With that plug fitted and installed proper, you should see an increase in voltage across the battery if you rev the engine up.

 

Thanks a bunch

 

The emphasis is AC voltage at the rubber connector on the block. Start bike and place meter probes one on each of the female terminals at the block. Does not matter what color goes to which terminal for AC voltage. Just make sure meter is set for AC voltage. Check the AC voltage produced with whats in the sticky or you manual.

I noticed in the pic that I can see one of the metal female terminals sitting in the rubber connector, but not in the other (top terminal in the rubber grommet at the block). Is the other metal connector there? Sometimes the connector can get pushed in towards the engine and out of the rubber part (not making connection to the volt reg lead).

The rubber in that connector gets soft with age and use. Fairly common problem and there are multiple threads discussing how to improve/repair the connection point without pulling the primary/clutch comp to access stator (if the wire is not pushed in).

The fix is a new stator just to replace that rubber connector, but the rubber will get soft again after a couple years. There was a recent thread describing a more permanent fix with new wires and a connector outside of the block, but that is getting ahead of things. For now, follow the Doctors advice and trouble shoot.

Bottom line is: is the stator putting out proper AC voltage? If yes, then is the voltage regulator regulating the voltage as well as converting it to DC voltage? If yes, then is the battery receiving and holding voltage? Also is your wiring and grounds solid and complete? That's the basics, YD

 

Good catch YD......

 

When I install a new stator (or even if have the primary chain off) I always pack the rear of the rubber plug with roofing silicon rubber sealer.&nbsp; It seals things off so no oil ever weeps out of the hole again and provides extra support behind it to help avoid the terminals sinking back into the cases if the rubber softens.<br>

 

did you replace the entire charging system? and how old is your battery?

 

Do you even think before posting???????

 

You state "I just finished replacing the charging system but it's still not charging"
Not really clear what you replaced.
I will guess it was the stator and regulator since the connectors look fresh.
No mention of battery change but i will guess it was at least tested since you were probably running on battery only.
That was an excellent catch by Yankee Dog regarding the upper female connection point.
I will also take another guess that voltage might not have been checked when the repair/replacement was performed.
But that is a lot of guessing.