Charging issue

Ok, here it goes. I have a 1982 kz550 ltd. This problem has just recently started. The battery seems not to be charging like it should. At an idle, it measures around 12.2 to 12.3.
At higher rpm ie. 3000 to 4000 it only goes to 13.5, give or take. Should this be a higher reading? Another problem seems to be, the fuse box with the 3 fuses in it, the 20 main is very hot!!! is this an indication of a problem? If the battery does drop, and the bike doesn't start, it does not take much of a charge to turn it over. a few hours. or the next morning the battery might not have enough juice.
I like to think that I have checked all the connections, the ground to the engine has been cleaned, etc........any input would be GREATLY appreciated! Thanks Forum

I'd say your charging system needs some inspection as to why the battery voltage is so low.

www.electrosport.com has a trouble shooting page on their website that can point you in the right direction.

Do you have a shop manual? It will have all the specs for checking the output of the alternator. I purchase all of my manuals at www.repairmanual.com

I'd also suggest checking and cleaning all charging system related electrical connections like the battery cables,fuse clips and starter solenoid terminals.

Brasso or other metal polish on a cotton swab will clean the fuse clips. If your fuses are the older glass tubed type they are usually available a auto parts stores under AGX designation 1"long,not the more common AGC 1 1/4" long.

Thanks MFolks, will take your advice, any input on that 20a main fuse getting so hot while idleing? Negative on having a shop manual, thats a gotta get item.

Corrosion/loose connections create resistance causing heat, so check these before ordering a alternator stator(wire windings).

I'd fully charge the battery and then have it load tested at the bike shop, looking for bad cells.

I found this website for a download:http://www.tradebit.com/filedetail.php/6905187-download-now-kawasaki-kz500-kz550-zx550-kz-500-550-zx

Don't know much about it, so look it over.

"At an idle, it measures around 12.2 to 12.3.
At higher rpm ie. 3000 to 4000 it only goes to 13.5,"....

12.2 at idle is a little on the low side....
Is this with all other current drawing devices such as lights, indicator lamps, turn signals etc... off, possibly disconnected?

13.5Vdc @ 3-4krpm, I would think this is approximately ideal for any KZ/GPZ... Being over +12Vdc, this battery should charge....

How old is this battery?

OMR

Nats82 wrote:

Ok, here it goes. I have a 1982 kz550 ltd. This problem has just recently started. The battery seems not to be charging like it should. At an idle, it measures around 12.2 to 12.3.
At higher rpm ie. 3000 to 4000 it only goes to 13.5, give or take. Should this be a higher reading? Another problem seems to be, the fuse box with the 3 fuses in it, the 20 main is very hot!!! is this an indication of a problem?

I believe the nominal set point is about 14V. At 13.5, it sounds like it should be charging but that maybe there is a big current draw loading it down somewhere. It could also be a flaky battery loading down the alternator. It could be a stator winding that is on it's last legs. hard to say exactly without isolating things.

When fuses are hot, first thing to do is replace them (they wear out). Second thing is to make SURE the contacts that grab the fuse are very clean or that will cause them to heat up. If the new fuse gets hot and/or curves in the center of the fuse element, you may have a problem.

Thats what happened to the new fuse I installed, it curved once the bike was running just a few minutes. The battery is brand new.Electrosport web site might be helpful, Mfolks recommened that. Since I owned the bike, headlight is on, and the front indicating lights are also when the bike is running, I guess that might be correct. Thanks for the help everyone, The witch hunt continues!

Just in case you need it....

D-connect the head & tail lights to see what your voltage is at....

Are you sure about the head light bulb being the correct wattage?

Ah well, good luck...

OMR

thanks Old Man Rock, I'm willing to try anything at this point. Headlight is correct wattage. Gotta get this working, I need some seat Time!!! Thanks again

Your manual should give you some testing/measurements that can be made on the rectifier/regulator combo unit...

Outside of that, really not much to the wiring in that bike...

Nats82 wrote:

Thats what happened to the new fuse I installed, it curved once the bike was running just a few minutes.

Sounds like you are very close to 20A. If it's wired like mine, the whole bike gets fed by that one including ignition. Then there are two sub circuit fuses (8A on mine) and one feeds a headlight and some small stuff and the other feeds turn signals, running light, horn, etc.

If you are curling a 20A fuse, I might have a look at the ignition. Is it stock coils? bad coils or low resistance coils could be pulling current.