Help: '97 charging system shutting down

Discussion in '3rd & 4th Generation 1990-1997' started by Tat, Aug 8, 2018.

  1. Tat

    Tat New Member

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    Hi,

    New ricks stator, regulator/rectifier, vfrness, battery, digital voltmeter, installed summer of '17. Ran fine all late last summer in to fall. Bike put into hibernation for our Canadian winter. Woke it up, ran great.

    However about a month ago bike shut down, thankfully on a back road with no traffic. Turned on my voltmeter (had shut it off trying to break the habit of focusing on it lol) and sure enough low volts. Checked wiring. Let it cool. Pushed it, started, volts showed 14.2, thought ok, lose wire.

    Since then, starts fine, runs great, volt meter shows the charging system always coming on at start up, 14.2 volts. Then within 5 mins or perhaps up to 1 hr running time shutting down, volt meter showing 12.6 and slowly decreasing. I can shut off the bike and turn it right back on and volt meter shows 14.2. Then repeat, charging system shuts down. I've done the "drill" as written too many times to count on the stator and r/r, I did so hot and cold. The stator never stops making power or going to ground, even when the bike is running and volt meter at battery shows 12.6. I stripped the bike, checked every connection including ignition relay, removed and cleaned every ground. I called and talked to tech at Ricks, he agreed r/r. The Canadian company I bought the stator and r/r from agreed to replace it and give me a credit. All the same I need a new back tire anyway. Happy, was thinking obviously I got a bad new r/r. Installed the new one, no change. Needless to say very disappointed.

    Before I either drop money for a mosfet r/r, even more loonies and toonies for a OEM Honda r/r, or listen to the growing voice in my head that is telling me to sell it as is for peanuts, is there anything else that could possibly be doing this? i.e. could a fine looking starter relay, the CDI, or possibly a well working keyed ignition switch internals somehow be "telling" my charging system "ok shut down now you are not needed?"

    Thanks in advance.
     
  2. squirrelman

    squirrelman Member

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    Look at the starter relAy connections. pull off the top plug and inspect for signs of overheating, melted wires, etc. remove two large nuts, and snap off the plastic part that holds the main fuse and other connections.

    new 031.JPG
     
  3. Tat

    Tat New Member

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    Thanks Squirrelman. I will have a another look at the starter relay. I had pulled the plug off the top and didn't seen any issues and left it at that not realizing I could dwell deeper into it. I will as you said, remove two large nuts and snap off the plastic part that holds the main fuse and other connections. Really hoping for a aha moment when I do. Much appreciated!
     
  4. Tat

    Tat New Member

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    Finally had time to again have a look at the ignition relay. No signs of burn. My relay does not quite look like the one in your pic Squirrelman. Pretty sure mine is not meant to come apart. Nonetheless I ordered a new one and expect it in tomorrow. Hoping that is the final part required to get the bike back on the road.
     
  5. squirrelman

    squirrelman Member

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    starter relays were updated after 1990 ( i think) from round to square, but i'm doubtful that a replacement relay is gonna help you. :Canada:
     
  6. needragr

    needragr New Member

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    So why do you believe that squirrel dude?
    Can someone post or direct the OP & any others that WILL encounter such problems to a Ignition current flow diagram or drawing &/ or step by step troubleshooting guide so that they dont waste time posting this same problem over & over only to suffer the same less than helpful responses~!?
    Its not that complicated.
    USE a VM. Check the voltage at on your battery. with power off & on. notice any drop in voltage.
    A weak or dying battery will cause all many of weird operating symptoms.
    Does you clock display and tick over?
    Do you get power ...to anything...when you key on? Yes . . go to <insert> No ..go to <insert>

    Perhaps there is thread with this info already? Cant it be made a sticky?
    Are the bikes so old now that no one cares?

    :surrender:
     
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