enduralast alternator installation problems

[oz_johnno]

Greetings all,
I recently forked out the $500 for this kit as I will be using my R65 to commute on and the standard alternator will not allow me to run my hot grips and heated vest while commuting in the melbourne australia winter.

It all went well and apart from a couple of stupid hickups I got the bike up and running.  The gen light was off and I measured 14.2V at the terminal.  this would sufggest that the alternator was working as advertised.

I put the bike back together and got to the front cover (covers alternator and hall effect sensor) and found that when I tightened it down, the motor stopped !!

obviously somthing is pinching or shorting or something, can you guys please give me an idea of where to look first??

Thanks in advance

OZ

[montmil]

Cover snugged down and the bike will not start. Did you remove the cover and attempt a restart? If the engine is purring, you may have either made a "ground" contact with the cover and a protrusion or- and this is what happened to me- one of the interior "webs" cast into the engine cover has pinched a wire, possibly the three-wire bean can lead, and shut down the BMW music. Front engine cover and the timing chain chest have several spots that will eat wire.

With the cover off, inspect the bean can harness closely. Look for a flattened spot. One or more broken 22ga wire/s may need some love.

Check back and let us know.

Monte

[Semper Gumby]

Do you still have the points ignition?

I would check the black wire off the condensor is not pinched - broken  - disconnected.

Good luck.

[oz_johnno]

Cover snugged down and the bike will not start. Did you remove the cover and attempt a restart? If the engine is purring, you may have either made a "ground" contact with the cover and a protrusion or- and this is what happened to me- one of the interior "webs" cast into the engine cover has pinched a wire, possibly the three-wire bean can lead, and shut down the BMW music. Front engine cover and the timing chain chest have several spots that will eat wire.

With the cover off, inspect the bean can harness closely. Look for a flattened spot. One or more broken 22ga wire/s may need some love.

Check back and let us know.

Monte

Yeah thats right Monte loosen it off and it runs just fine.  I will have a look for flat spots today.  When you say 'need some love' what does that mean??

to me 'show some love' means something that its physically impossible with a wiring harness.

Cheers

OZ

[nhmaf]

In this context - Monte is just trying to indicate that some careful attention and repair may be needed.  

[oz_johnno]

right...... well I went out and examined the wiring to the bean can and yup, there were flat spots in the wiring, I carefully re-ran the wiring so that it didnt get jammed, tightend the cover back up and voila...... it ran like a dream.....

awesome, stable voltage, runs sweet.

Cheers

John M

[wa1udg]

You probable should replace that wire, or at least put some tape on it.  You could use heat shrink tubing but in its unshrunk  state it has to be able to fit over the connector.  It is is too large, unshrunk, it won't shrink to a tight fit.