the old Reg/Rectifier... or dodgy headlight circuit?

Discussion in 'Mechanics Garage' started by KiwiRC36Fan, Jun 30, 2020.

  1. KiwiRC36Fan

    KiwiRC36Fan New Member

    Country:
    New Zealand
    Joined:
    Dec 21, 2018
    Messages:
    26
    Likes Received:
    7
    Trophy Points:
    3
    Location:
    GodZone (Auckland New Zealand)
    Map
    Hiya

    I replaced my battery a few months back (December) as the old one was losing charge - and I had short runs to work
    The new one has started dropping as well - although I'm running 20+ minutes each way to work, so I connected a built in voltmeter.

    Noticed it's running at 12.4-12.5v when cruising at 4,500-5,000rpm
    Hmmm, I thought - probably reg/rect
    Then I switched lights off and it jumps up to 14.4-14.5v

    Uh oh - I now suspect dodgy wiring/connectors on my headlights. (I always ride with lights one, and never use the switch to kill them independently)

    has anyone else had this before?

    Reg/Rect was replaced about 2 years ago (17,000km)

    1997 VFR 750F (Gen 5?)
    I have a couple of ancillaries that I figured were contributing to the drain - GPS/Alarm/Cameras/etc - so i was surprised to find the headlights caused a voltage drop of around 2 volts

    I then jumped online to look at installing a new relay circuit for the headlights and found the H4 dual headlight wiring kit from Eastern Beaver (I've had good dealings with them before) - have any of you tried? What are your thoughts?
    http://www.easternbeaver.com/Main/Wiring_Kits/H4_Kits/h4_kits.html

    Do this first THEN reg/rectifier if it doesn't resolve the issue?
     
  2. Terry Smith

    Terry Smith Member

    Country:
    Kuwait
    Joined:
    Nov 18, 2013
    Messages:
    2,727
    Likes Received:
    625
    Trophy Points:
    128
    Location:
    Auckland, New Zealand
    Map
    Another possibility would be if the connection between the RR and the alternator was a bit weak/corroded so the current flow was low; with the extra load from the headlights you would see a drop in charging voltage I think. Not sure on the RC36 but my RC46 certainly started to show reduced voltage when running when the RR/alt connector got some corrosion in it. Responded well to being cut out and hard-wired and I saw the voltage go from 13.3 to 14.1 as a result.
     
  3. KiwiRC36Fan

    KiwiRC36Fan New Member

    Country:
    New Zealand
    Joined:
    Dec 21, 2018
    Messages:
    26
    Likes Received:
    7
    Trophy Points:
    3
    Location:
    GodZone (Auckland New Zealand)
    Map
    ahh - good tip! I'll have an inspect of it today.
    Any feedback on the Eastern Beaver headlight wiring kit?
     
  4. fink

    fink Member

    Country:
    United Kingdom
    Joined:
    Mar 6, 2013
    Messages:
    1,590
    Likes Received:
    457
    Trophy Points:
    113
    Location:
    Ardnamurchan Penninsula, Scotland
    Map
    Check your charging system Ideally it should be reading around 14.5 v @ 5k revs with lights on main beam.
     
  5. Terry Smith

    Terry Smith Member

    Country:
    Kuwait
    Joined:
    Nov 18, 2013
    Messages:
    2,727
    Likes Received:
    625
    Trophy Points:
    128
    Location:
    Auckland, New Zealand
    Map
    The manual specifies 14.0-14.8V across a properly charged healthy battery with headlight on high beam, at 5000rpm.
     
  6. raYzerman

    raYzerman Member

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    1,228
    Likes Received:
    450
    Trophy Points:
    113
    Location:
    Millgrove, ON
    Map
    IIRC, those headlight kits were designed to provide larger gauge wiring and full power to the headlights. Your stock wiring is likely OK, except for that R/R... I'd be replacing it with a mofset regulator at the first opportunity if it was me and get rid of all those OEM connectors. Once the charging system is fixed up, you can see if you still have issues elsewhere, if any.
     
  7. KiwiRC36Fan

    KiwiRC36Fan New Member

    Country:
    New Zealand
    Joined:
    Dec 21, 2018
    Messages:
    26
    Likes Received:
    7
    Trophy Points:
    3
    Location:
    GodZone (Auckland New Zealand)
    Map
    I found the most like issue... ordered new Mosfet R/R and wiring kit from Jack (www.roadstercycle.com) who is awesome. but he's out of stock and away, so I'm going to try to track down something local in the meantime... EasternBeaver also do the R/R kit as well, so I guess I'll be ordering that in the meantime

    Cheers team!
     

    Attached Files:

  8. Terry Smith

    Terry Smith Member

    Country:
    Kuwait
    Joined:
    Nov 18, 2013
    Messages:
    2,727
    Likes Received:
    625
    Trophy Points:
    128
    Location:
    Auckland, New Zealand
    Map
    Yep, that will do it all right. What you are seeing is the result of water entering that connector, starting a bit of corrosion. The corrosion increases the resistance so it generates heat and starts to melt the plastic of the connector. Unless the corrosion/melting has gone too far, you could probably clean that connector up, add dielectric grease, and carry on.
     
  9. KiwiRC36Fan

    KiwiRC36Fan New Member

    Country:
    New Zealand
    Joined:
    Dec 21, 2018
    Messages:
    26
    Likes Received:
    7
    Trophy Points:
    3
    Location:
    GodZone (Auckland New Zealand)
    Map
    yes, I replaced the dodgy plug with direct terminals and grease... I had ordered a new R/R and wiring kit, am currently tracking down another supplier, or will wait till Jack gets them in again

    Interestingly enough, even with direct connection the charge is still low when the lights are on - at all revs.
    When I get some days off I'll do the full charge test and make sure the ol' stator is up to the task as well!
     
  10. Terry Smith

    Terry Smith Member

    Country:
    Kuwait
    Joined:
    Nov 18, 2013
    Messages:
    2,727
    Likes Received:
    625
    Trophy Points:
    128
    Location:
    Auckland, New Zealand
    Map
    How is the 3-pin connector between the RR and stator? That is where my VFR showed a voltage loss.
     
  11. KiwiRC36Fan

    KiwiRC36Fan New Member

    Country:
    New Zealand
    Joined:
    Dec 21, 2018
    Messages:
    26
    Likes Received:
    7
    Trophy Points:
    3
    Location:
    GodZone (Auckland New Zealand)
    Map
    yeah it was one of the three yellow wires from the stator that was burned.... and replaced with a good fitted terminal
     
  12. KiwiRC36Fan

    KiwiRC36Fan New Member

    Country:
    New Zealand
    Joined:
    Dec 21, 2018
    Messages:
    26
    Likes Received:
    7
    Trophy Points:
    3
    Location:
    GodZone (Auckland New Zealand)
    Map
    Still low voltage on idle.... ordered a replacement R/R Harness from EasternBeaver (Jack @ Roadster is all out of stock) and a local Shindingaling FH020AA

    Now impatiently waiting for delivery
     
  13. raYzerman

    raYzerman Member

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    1,228
    Likes Received:
    450
    Trophy Points:
    113
    Location:
    Millgrove, ON
    Map
    I have a prediction...... things are gonna get better!!
     
    KiwiRC36Fan likes this.
Related Topics

Share This Page