83 550E stator & regulator

[posplayr]

I've been trying to find out the answer to this but haen't found an answer yet. Can anyone tell me what the current draw of the main hot wire for the entire bike should be? (Basicly the current through the DC output wire of the regulator.)

I measured it on my bike and it's around 13-14 amps. Does this seem appropriate? My guess is it's at least close. I also measured the current through the coil relay, ( the wire right from the battery to the relay contact set), and it's about 5 amps. I figure the headlight, tail light, and gauge lights have to ammount to about annother 5-7 amps. I also have to guess the ignition box and various dropps across the key switch, right handle bar kill swith, brake switches, etc would be annother 2-3 amps. Added all up it seems in the ball park, (5A + +6A + 2.5A = 13.5A).

I know all of my battery to fuse box and ground voltage dropps are good because i did vmeasure them. The ground voltage drop is exactly zero because I have done the single point thing, and the drop across the battery + and the supply side of the fuse box is .08 whitch is the same as from the battery + to the regulator DC output.

As allways, experienced input is welcome and appreciated.........

Thank you.

.
Your measurements sound correct . Not sure why you thnk the electrosport r/r is of any particular advantage? The electr osport stator on the other hand I feel is good value. If you have a persistent issue with burning up stators get the compufire series r/r or see if you can sneak by with a Honda r/r. Isuspect with that 550you rev it retty well and so yur are stressing your stator to the point of smoking it.

[don]

Thanks for the responses fellas.

( Posplayr, to answer your inquiry about why I put the E-Sport R/R in..., because not only was it recommended by others here but there is a link right in the stator papers, ( the holy grail of electrical here), for it. Even the most unobservant idividual couldn't miss the suggestion......).

The reason I'm asking all of this is because I've gone through all of the above stuff with the stator and R/R because they had expired. All seems well with the new parts. Good voltages etc. I looked under the seat to make sure all was well with the connectors and one was starting to look like it had gotten hot and disscolored. It was the R/R DC output connection. That's what prompted me to start measuring actual current in stead of voltage. That one connector got so hot that it melted the plastic housing the male spades are in on the E-sport unit. I have since cut that wire out of the E-sport plug and put a high amp, (50A @14VDC), connector in it's place. My guess is this is what happened when I smoked the stator and R/R. I think the same thing happened and the connector melted to the point that the DC output and one of the AC wires shorted.

With all that said, you can see all of my voltage dropps are also in good order, are there any thoughts as to why I am experiencing this? I would really hate to spend all of that money and time again. ( I've put about 300-400 miles on since the new parts). I just don't know if I missed anything or did something incorrectly.

Thanks.

[don]

Forgot to mention, the voltage drop measurements were before I repaired the connector, they were with the " overheated " connector. With the new connector the voltage drop on the positive side is .01 volts.

[don]

Well, I've put about 300 miles on since my repair and there is no signs of reoccurenc of my issue. I have to believe my problem was with my execution of connecting the two parts. I may have not got the connector "plugged in" correctly the first time. all is well so far........... I take the seat off and check after every ride to look.

I know we banter some posplayr, but I do believe you're correct about you're persistance about connections.......Thanks..........

[don]

Here's a couple of pics of the connector on my Electrosport R/R.

The yellow wire with the blue crimp on connector is one I did a while ago because that one had started to melt soon after i replaced all of this. I now have all blue crimp-ons.

http://i510.photobucket.com/albums/s350/donmod/DSC00172.jpg

http://i510.photobucket.com/albums/s350/donmod/DSC00174.jpg

[posplayr]

Here's a couple of pics of the connector on my Electrosport R/R.

The yellow wire with the blue crimp on connector is one I did a while ago because that one had started to melt soon after i replaced all of this. I now have all blue crimp-ons.

http://i510.photobucket.com/albums/s350/donmod/DSC00172.jpg

http://i510.photobucket.com/albums/s...d/DSC00174.jpg

sounds like you did a lot of work and it has all paid off. If you used dielectric grease it should stay the way. Give those connections (modified stator pages phase A)a test in about 6 months just to monitor for any degradation.

[koolaid_kid]

I just finished the electron dance with my bike, and what you have reported is almost everything I did. The other thing I did is go to the front of the bike and check all the connectors. Mine were in the headlight shell. I found two melted connectors, right handlebar switch and ignition switch. I got the wiring diagram out and traced out the wires that had failed in the back and traced them to the front. That told me which connectors to check first, and my assumptions were correct.
Fixed those and now everything appears to be happy.

[don]

If you will refer to my first post of this thread you will see that over the winter of 2009/2010 I litterally took every connector on the bike apart and mechanicly cleaned them then applied a generous ammount of dielectric grease, (as to encapsulate each connection with it). I squirt it in the hole where the wire goes, on the wire, fill the female end with it, and coat the male end..............encapsulated..............

The only reason I can think of for this latest failure of this connector is either poor exicution of repair or poor selection of the female plugs to mate with the E-sport males.

After replacing all connections for the charging system with the "blue" connectors in my latest photos, I rechecked all the voltage dropps and all are once again in order. This made me quite happy, as there doesn't seem to be any immediate damage to any parts besides the original E-sport connector. I thought all was good the last time too. I guess another 1000 or so miles will tell me.

Thank you all for your comments and help.

[posplayr]

When I first installed an Electrosport R/R into my ED, I used the connector hat came with the unit because is matched the R/R connector in the brand new OE harness I had.

After starting the bike I measured the voltage at idle which was about 12.5V and when I rev ed it up i dropped to about 12.0V .

I found out the R/R was getting very hot as well. After cutting off the connector that was poorly crimped everything was restored to normal operation. Seems like you has similar experience with an Electrosport R/R's crappy crimped connector .

[don]

Posplayr,

Didn't want to come right out and say it without giving others a chance to prove me wrong, buuuuut, I think the E-sport connector, (metal parts), were pretty cheap. Real flimsy.

As mentioned prior, one leg of the stator started to show signs of heat early on, when I repaired that leg with the "blue" connectors I use, that one held up just fine.