WR 450 Charge/lighting Problems.
Posted March 29, 2010 - 01:16 AM
I have a problem that is doing my head in! It is a long story but stay with me! Many other threads I have read cover bits and pieces of my problems but none have fixed it. Here goes!
I have an '06 wr 450. My battery seemed to be getting down (after 3 years- it's a stock yuassa) so I kick started to get going. While out riding, at low revs, it would carry on popping and stalling and as it turned out, the battery was so flat the bike hardly ran down low, but kept going all the same. We came to a stop for a break, but when I went to leave, I had no dash lights, starter or anything. A couple of kicks later and it fired so I rode it home and put it on charge and the next day all was normal (dash, electric leg ect).
Time to follow the manual and it's testing procedure.
With the bike running, I had no headlight and no charge, checked everything as per instructions and it seemed to be the regulator/rectifier, so I replaced it with a new (genuine) one much to the delight of the local supplier who told me this would fix the problem.... It did not. Took it for a ride, same problems. Kick started fine and rode home. Tested every thing again, resistance tested the stator and so on.
This is what i've come up with. Sometimes the problem is gone and other times it is there. Somtimes when it will not charge or run lights, I can give it some big revs and it comes back to life! Bash it over a jump or two and out they go again. (i had the multi meter strapped to the bars!)
I tested the output of the two stator outputs while hooked up and they were low (like 11-12v) and they actually dropped a bit with revs, so I un-plugged them and there was around 50vac each.
I'm at a loss and feel like putting a match to it!!! Any help appreciated.
Posted March 29, 2010 - 09:50 AM
Posted March 29, 2010 - 05:24 PM
Edited by timare, March 30, 2010 - 01:21 AM.
Posted March 30, 2010 - 09:01 AM
If you are losing both lights (ac) and charge to the battery (dc) at the same time, and have already replaced the reg/rec with another stock unit, this would lead me to believe that your problem is stator related or again a connection problem between stator and reg/rec or reg/rec and whatever is downstream. You have verified that you stator is good so we're back to the connection issue. Make sense? This is not a battery issue as the stock lighting should still work fine with a battery that is shot or a good one as the lights on your bike run off ac.
I am by no means an electrician, so this is just my .02, but everything you've said would lead me to this being more a connection problem than anything else. And bad connections are a bitch to find sometimes, but fortunately we're talking about a bike and not a house. Take a real good look at all the connections to and from that reg/rec. Unplug the plugs and plug them back together. I have already found plugs on my bike that will not stay together without a zip tie as the little locking tab does not work......and it looks like it is otherwise plugged together, but not making complete contact. Check fuses as well.
You're going to find it!
*** Edit- -you've already done a lot of unplugging and replugging by the sound of it. What about the various connections that are not directly related to the reg/rec? By that, if you had a loose connection up by the on/off button that basically affected the entire bike (lights/ignition/charge to the battery) this would likely produce some of the same symptoms you are experiencing. You had mentioned that lights cut out over jumps as well. And double check that plug that goes into the spark plug cap (coil). That is the one that I cannot get to stay together by itself.
Edited by OUTERLIMITS, March 30, 2010 - 09:23 AM.
Posted March 31, 2010 - 01:20 AM
Posted April 01, 2010 - 08:20 AM
Posted April 01, 2010 - 09:21 AM
Took a little piece of tinfoil to fix
Posted April 02, 2010 - 02:44 PM
Posted June 15, 2010 - 02:05 AM