More charging problems...yay..

Hey all,

I've been dealing with this problem in the shop on n off for about a month now. Just a heads up the wiring is not stock and is more simplified. Started with my battery getting over cooked on the road. I never had any problems before then (1500ish miles) with the new wiring. I take it back to the shop, manage to blow all the lights but no fuses. (of course! ) Obviously it sounds like a R/R problem, so I buy another R/R from a kind gent on here. Ends up that the new units doesn't solve the problem and the stator tests fine with no shorts and/or good resistance between yellow wires.

After some troubleshooting, both R/R's bench tests went well. I unhooked the main wire I have supplying power to the starter button in the right handlebar housing and actually made things better; but still not where they should be. With the new battery it rests at 12.6v, idles at 17v with the R/R attached, 12.5 w/o R/R. If I press on the brake pedal with a new light installed while running, the reading drops about 4v to 12.7 while idling, and the idle climbs slightly. When not running, and I press the brake switch the reading drops only .1v

I'm just trying to figure out what is going on now. I'm almost tempted to just run it with the brake light switch on the whole time to prevent boiling the battery. Does this sound like short somewhere or extra voltage somehow getting through the R/R?? Little stumped and wondering what the guros have to say.

V/R

Kev

Can you go into some detail, what bike/ Motor/ Year etc. Is this a Kawasaki System? 5 or 6 wire R/R?
If 6 wire R/R from Kaw, then do you have a Brown wire on the R/R hooked to a Key On switched 12v source that is nearly the same as battery voltage? This would be my "Overcharging" Guess. This sense wire needs to see Batt Voltage to have the Regulator work correctly.

When you "simplified" the wiring did the stuff you remove include anything that look like what's in the pic below? Ed

Motor Head wrote: Can you go into some detail, what bike/ Motor/ Year etc. Is this a Kawasaki System? 5 or 6 wire R/R?
If 6 wire R/R from Kaw, then do you have a Brown wire on the R/R hooked to a Key On switched 12v source that is nearly the same as battery voltage? This would be my "Overcharging" Guess. This sense wire needs to see Batt Voltage to have the Regulator work correctly.

It's the 96 KZ1000P with 6 wire system R/R. I have the brown wire spliced into the w/r wire which goes to a fuse and obviously battery.

Ed- I don't recall seeing this specific piece. I took out the rats next more then half a year ago, and I'm quite sure I don't have it on the ride still.

Brown going straight to Red/ White, back to battery with No Switch would probably cause a draw on the battery when not running.
Are you sure this connection is working? This is the sense wire for the R/R. Also the excess voltage must Shunt back to ground on the Black/ Yellow. Good clean connection here?

Yes sir, it's working as far as I know. Worked well for the couple of months I was on the road.

And there's no resistance between the ground wire from the R/R to any metal piece on the frame.

V/R

Kev