WR450 lighting/charging issues
Posted January 04, 2011 - 10:03 AM
Note:US WR models only.
I was having a real hard time tracking down why my WR lights were super dim, and why the battery kept going dead. There was only 3 volts going to the taillight, and the headlight would start off pretty bright after a full battery charge but gradually dim. Also, it wouldn't get brighter as the bike revved.
Checked and cleaned all the connectors I could find. Checked all the ground connections. Did all the checks of the reg/rec and AC magneto as per manual. The output voltage of the r/r was only 12.4 or so, actually it was only battery voltage. The AC mag ohmed out fine. Bad r/r, according to the manual.
Got a used one from ebay, hooked it up. No better. Stumped. 2 bad r/r?
Here's the deal. Behind the headlight shroud there is a 6 pin multiplug wrapped in elec tape. Peeled off the tape and pulled the plastic cap off. There is a 6 pin metal jumper to connect all the leads together, and apparently ALL the lighting/charging juice runs through it. The jumper replaces the multi-switch on non-US WRs which control the lights. It is NOT in the schematic.
Cleaned the jumper (a little corroded, gets a lot of water but very little ventilation) and the plug. Used dielectric grease and wrapped it all back up in a double layer of electrician's tape.
Problem solved. The lights are way brighter than I ever remember, and the output from the (original) r/r is bang on spec.
Moral-when the manual's first step for diagnosing elec faults is
'check: couplers and leads connection-rust/dust/looseness/short circuit-repair or replace'
they mean it. Even if it's not depicted in the wiring diagram.
Hope this helps someone, and saves them buying parts unnecessarily.
ps regulator/rectifier for sale. Works fine. Only used for testing purposes...
Posted April 06, 2011 - 11:20 AM
Posted April 06, 2011 - 05:57 PM