Electrical - Grounds And Other Contacts

[BPT]

I wanted to clean up and tighten my grounds and other contacts.  Anything to pay special attention to or any particular ones to make sure to find?

I am having a charging problem but haven't figured out why yet.  No idea if this would help but I wanted to do this anyway.  Other than the obvious battery ground, I was  hoping to be pointed to any that might be of particular importance or that might be overlooked.

                       Thanks

[Barry]

For charging problems you have to do the 3 connections from the alternator stator to the diode board, all the outgoing connections from the diode board to the VR and back to the battery plus the connections and brushes to rotor. This diagram shows them all with a little connector symbol.

You have a wiring diagram it will show all of the collective earth points in the wiring harness where the brown wires come together. Mine has several with the one under the tank on the coil mount being a common one to cause problems.

[BPT]

Thanks  Barry, that's exactly the kind of info I was looking for. I had a diagram I was staring at but was worried that the spots where they actually connect might be hidden or hard to find and see when looking at the bike.
Thanks for steering me in the right direction.

                                      Cheers

[montmil]

I had a diagram I was staring at but was worried that the spots where they actually connect might be hidden or hard to find...

You've got that right! It all looks so easy... Plus, there's the occasional PO (Previous Owner) that goes his own way with odd-colored wires, poor terminal connections and just plain ol' bad juju.

Don't be That Guy.

BTW, Snowbum has some full color and large wiring diagrams. Worth a look.

[BPT]

Don't worry, I'll do everything possible not to be that guy. I figured by asking here it would help make sure I hit the important spots and hopefully not miss anything.  I was also hoping to save some time hunting for things.

I've got the Clymer manual and Rick's Electrical guide.  I think that I have Snowbum's diagram downloaded somewhere (need to check those).  I've been looking them over but figured I'd better ask for some real life direction.  With tips like Barry's at least now I can go backwards from those areas he mentioned, if necessary.

Those diagrams look like nice, pretty, colorful art projects but in reality what you usually get when you're "under the hood" is a big half-eaten pile of spaghetti.  Served on a dirty plate.

I'll probably try to do this next week, I'll report if I find anything.  Of course, any and all advice is welcome.

                              Thanks

[nhmaf]

All the usual stuff - if the GEN light won't come on when you first turn the key, then you're going to have a charging problem.  It it won't light while idling and then go out while up at 3K RPMS, you're going to have a problem.  In both cases - first check that the bulb isn't blown.   Clean all terminals on the voltage regulator (and consider possibly ordering a spare, as they do die after 15-20 years or so).  Another common source of "no -charge" problems concerns the brush connections at the alternator - the brushes wear down or the springs get weak and don't make contact.
If you have a digital voltmeter/multimeter and know how to use it, it will greatly help your troubleshooting process.

[montmil]

This wiring diagram came with my 1981 R65.

[montmil]

May be of help.

[Barry]

Can't see that working - they shorted out the flux capacitor.

[BPT]

That's perfect Montmil, thank you!  This is exactly how I envision electrical work.

Unfortunately, all of the big box stores I've checked with are out of stock on scarab beetles, so looks like I'll have to put everything on hold until I can find a specialty store that carries them.  Pretty sure that's the key to my charging problem.   That's gotta be it.

[Tony Smith]

That's perfect Montmil, thank you!  This is exactly how I envision electrical work.

Monte is a bit on the eclectic side of things.
What you probably need is replacement wiring harness smoke - electricity is transmitted by smoke trapped in the strands of the copper wire in your bike's wiring harness. when the smoke gets out the electricity is no longer transmitted.

Below is a picture of the Lucas service kit for re-infusing smoke into Lucas wiring harnesses. You will have to contact Bosch and obtain the Germanic equivalent.

I most certainly do not recommend the use of Lucas wiring smoke in Bosch wiring harnesses due to well known issues of incompatibility.

[BPT]

NHMAF - Unfortunately (or maybe fortunately?) all of my lights are working ok and at the appropriate times, rpm's, etc.  I've been reading up on some of the troubleshooting tips and the obvious things like that seem to be alright.  My only indication is that after riding a while it just doesn't have enough juice.  I thought that it was partially too much low rpm riding but last week I found that not to be true.

I had looked into getting a voltage regulator both as a spare and also an upgrade.  It was mentioned on here before about some of the adjustable or higher voltage ones (can't remember which).  Was considering one from EME.  Hadn't done anything about that yet though.

I have a meter, can't say that I know how to use it well.  I do follow directions though.  When I go through my contacts and such, I was going to try some of the troubleshooting things I read, at least the simple ones involving the meter.

I will check the brushes and connections.  I was going to start with simple stuff like cleaning and snugging things up and looking for any obvious things then see if that makes a difference.  I'm ignorant but willing to learn so feel free to throw out any other ideas.  I'll see if they are within my limited abilities.

I found a local place that will make battery cables fairly cheaply, considered that as well since the age of mine are unknown.  I've been reading about people adding an additional ground and that is supposed to be helpful.  Any thought on that?  Good, bad, indifferent or an added complication?  Sounds simple enough but not sure if it's worth anything?

[montmil]

Rick Jones, a Northern Alabama lad, runs Motorrad Elektrik. I run his upgraded, electronic voltage regulators and see better and happier batteries. I would also suggest his nifty manual, Classic Boxer Charging Version 3.0. It's my go-to info for charging and electrical questions. Surf his products. Cool stuff.

<http://www.motoelekt.com>

[BPT]

I do have that book, Montmil.  I ordered that a while back along with the Beacon taillight from him. I talked to him a couple of times, seems like a really nice guy.  And I know that his products have a good rep.  It's been a while since I'd been on his site but just happened to be looking at it this evening.  I will be checking out the regulators there.

[BPT]

Thanks Tony.  I definitely know about both the complexity and superiority of German products, engineering and technology.  I will most certainly look into finding the proper, correct German smoke.

 I'll assume that there is an equally rare and difficult to use German made tool or apparatus (with a price to match) necessary for the re-introduction of the smoke back into the harness?  Maybe someone can provide a part number?