Charging System Failed

[Bob_Roller]

Worked a double shift yesterday, got out at 2300 .

Bike started normal got about 2 miles from work and the instrument lighting seemed quite weak, thought, it's time to get LED replacement lamps .

Got on the expressway about two miles later, got behind another vehicle and noticed that I didn't see the reflection of three lights, headlight and two driving lights, the headlight was missing .

Turned the headlight switch to high beam, lost the driving lights then .

Returned the switch to low beam and the driving lights  came back on, but now noticeably dimmer .

Got the bike home no problem .

Shut the engine down then turned the key on, no 'GEN' light, removed the back trim  of the instrument cluster and swapped the 'GEN' light bulb with a turn directional bulb, still didn't work .

Looks like I most likely have a failed rotor .

Tear into it this afternoon .

Glad I keep the battery on a battery tender all the time !!!!!

Didn't notice the light didn't come on when I left for work at 0515, if I hadn't worked late, I might not have noticed anything was amiss !!!

[montmil]

At least the rotor is an easy check. Post up results. We don't need our newest "Global Moderator" running around Phoenix without lights. "No. no. Not on the runway."

[Bob_Roller]

I have deferred this troubleshooting to a 'cooler' time, it's 114 F. (46 C.) at 1600 .

Time for a few adult beverages (homebrew) .

[badbmwbrad]

While attending Airheads at the Aerodrome this weekend, I read Rick Jones' Classic Boxer Charging.  In it, Rick advises using a coin to jumper wire across the rotor slip rings then turn on the ignition key.  

If the generator lamp is on with jumper applied if the light is off when jumper removed then the rotor has an open circuit then replace the rotor.

[Bob_Roller]

Brad, thanks for the info, I've got the troubleshooting guide from Rick Jones, the owner of Motorrad Elektrik .

With the forecast temperatures in the suburb of hell that I call home for the next week 111-114 F., I might not get to this, until I can work on it in the early morning hours on my first day off, next Sunday .

Pretty much expected some component of the charging system to fail, but I thought it would be the diode board first to fail .

Last time I had the board out, it was blackened or charred for about .5 inches, 12 mm around the diodes .

I run PIAA 40 driving lights, 55 w each for the last 8 years, so this was expected .

For the interim, I'll remove the rotor from the '84 LS/parts bike and install it on the '81 R65 .

Haven't made up my mind on which way to go on the rotor, get a rebuilt or new one, but an upgraded Omega or Thunderchild diode board will be installed in the not too distant future .

[Justin B.]

I've had two rotors take a dump.  One in the '95RT and another in the '81 RT.

[Bob_Roller]

With 31 years and 87,000 miles of use, I feel I got my money out of it !!!

[tvrla]

Haven't made up my mind on which way to go on the rotor, get a rebuilt or new one...

I'd recommend getting the Motorrad rebuilt rotor. They're remanufactured with current materials and technology and much improved over the stock rotors. Rick warranties them and when he was first rebuilding them kept getting them back from the hot-rod racer types. He kept working to improve them till they stopped coming back.

[Justin B.]

I bought both of my rotors from Euro Motoelectrics.  He carries new rotors for under $100...

http://www.euromotoelectrics.com/default.asp

[Bob_Roller]

Got the problem solved, not the rotor !!!!!!

I asked myself, what was the last work you performed on the bike ?

Answer, replaced and rerouted the negative battery cable .

I also added a large diameter wire from the main grounding point on the bike, to the battery negative cable .

I had to remove the two screws that hold the voltage regulator on, the main ground on the '81 and later bikes, is secured to the frame with one of the screws that holds the voltage regulator on, in the process, must have pulled on the connector that goes on the voltage regulator and loosened it and didn't realize it .

The connector was laying on top of the engine .

Put the connector back on, charging system works normal now .

[montmil]

D'oh!

I do hate it when I shoot myownself in the foot. On the bright side, Bob, you had not yet ordered a new rotor. [smiley=whistling.gif]

[Red_Hen]

Good Handywork, Bob!

[tvrla]

What's even worse is having to tell everyone the truth.  

But the truth, even though it's not the easiest to swallow sometimes, makes the best stories.

[Bob_Roller]

My question is, I only take the bike out on the weekends to work, how long has the connector been off ?

I did this work three weeks ago .

If I hadn't worked late, I still wouldn't know I had a problem .

I haven't been vigilant in looking at the lights in the tachometer when I start the bike .