Electrosport R/R and Stator still not doing the job...

[phillygrimace]

This harness seems to be pretty melted, and has a few cancelled wires right on the harness (snipped at both ends). Does anyone know what this one is attached to?

[OldVet66]

That's a proper mess. fifteen volts will cook your battery. I hope you meant at 5.000 rpm it was between 14 and 15 volts. Download your shop manual, it should have a wiring diagram. http://www.mtsac.edu/~cliff/storage/...-SD-ED-ESD.pdf

[phillygrimace]

That's a proper mess. fifteen volts will cook your battery. I hope you meant at 5.000 rpm it was between 14 and 15 volts. Download your shop manual, it should have a wiring diagram. http://www.mtsac.edu/~cliff/storage/...-SD-ED-ESD.pdf

Will sort through the wiring diagram to figure out what that may be. I was just saying that a fifteenth of a volt extra is being drawn with the "low beam" setting, which I believe now to actually be both low and high beams at the same time. Not fifteen .

Is this a common issue with these wiring harnesses, or old wiring harnesses in general? What i mean by common issue is - melty connectors. What normally causes this

Thanks for stickin with me guys, i'm the first to admit i'm a newby and need all the help I can get!

[JEEPRUSTY]

What a mess POs all suck.

[tom203]

If your low beam filament and high beam filament came on at same time, this would draw maybe extra 5 amps from bulb ground to frame/harness ground. But I'm suprised bulb didn't overheat and just flame out.

[posplayr]

1.) key off................Normal 12.7 volts-12.9 volts
12.7
2.) key on (but not cranking with lights for 10 sec).....Normal 12.2-12.5 volts
12.4
3.) at idle (1500 rpm).....12.6volts - 13.2volts
12.6
4.) at 2500 rpm 13.5 -14.0 volts
12.9
5.) at 5000 rpm.....14.0 -15.0 volts
13.1 this test -- have seen as high as 14 though in past couple of days
6.) key off.....slightly higher than measurements # 1 (12.8-13.0 v)
12.8

Looks like a very healthy charging system I don't like the 15.0V but the old OEM spec goes as high as 15.5V IIRC

Most of the newer R/R's have a setpoint at 14.25.

[posplayr]

If your low beam filament and high beam filament came on at same time, this would draw maybe extra 5 amps from bulb ground to frame/harness ground. But I'm surprised bulb didn't overheat and just flame out.

Yep .................

[phillygrimace]

Yep .................

I'm wondering if this is maybe the reason for the melted connectors on the headlamp, and down on the fuse box connector (the one pin that is connected to the lamp fuse within the box) ?

[OldVet66]

Candlepower has a nice ceramic replacement socket. I put one on my bike. http://store.candlepower.com/cesohb90be.html

[phillygrimace]

Looks like a very healthy charging system I don't like the 15.0V but the old OEM spec goes as high as 15.5V IIRC

Most of the newer R/R's have a setpoint at 14.25.

I haven't seen 15.0v at all actually.. not sure where you guys are seeing that I wrote that. The highest i've seen with the headlamp fuse in is in the high 13s. Not sure if this means anything, but when the turn signals are firing, the headlamp is dimming in unison with the blinker

[phillygrimace]

Candlepower has a nice ceramic replacement socket. I put one on my bike. http://store.candlepower.com/cesohb90be.html

Ah, this looks like something I will be doing. Does anyone know of a replacement socket for the fusebox?

[posplayr]

I haven't seen 15.0v at all actually.. not sure where you guys are seeing that I wrote that. The highest i've seen with the headlamp fuse in is in the high 13s. Not sure if this means anything, but when the turn signals are firing, the headlamp is dimming in unison with the blinker

You typed 14.0-15.0. which granted is a wide range but that is what your posted.

realize even a difference of 0.2-0.3 volt readings can give a different diagnosis of state of charging system depending upon which numbers so in that regard the only advice being offered is that 15.0 is too high.

[Andrew Vanis]

he was quoting your typing here - http://www.thegsresources.com/_forum...92#post1272192

"5.) at 5000 rpm.....14.0 -15.0 volts"

his data (in post# 13 above) is -

13.1 this test -- have seen as high as 14 though in past couple of days

[phillygrimace]

he was quoting your typing here - http://www.thegsresources.com/_forum...92#post1272192

"5.) at 5000 rpm.....14.0 -15.0 volts"

his data (in post# 13 above) is -

Yeah yeah, simple misunderstanding. I was quoting that though.

So after a few hours of tearing apart the headlamp basket and really looking into the harness at that end of the bike .. it seems like some kind of wiring modification was done after some sort of small electrical fire happened. There is one plastic socket that appears to be original and pretty melted. All the wires except one yellow with white stripe have been eliminated going through this socket towards the accessories. The side of this socket going to the main wiring harness run stays in tact, though. Also, there is one black with white stripe wire that is loose (terminated by itself) , and two brown (brown looking -- a bit color blind i am) wires that are loose and have plastic on the end terminating them together hanging inside the basket. These three wires (the black, and two brown) come from the same run as the headlamp wires. The headlamp socket (3 wires) is pretty melty, but still makes a good contact with the bulb (i assume because the lamp is working, and switching between high and low).

When on High beam, the voltage meeter gives me ok readings throughout the basic check. When on Low beam, the headlamp seems to draw a bit more voltage. Still, I am not seeing a solid 14.4 volts at 5,000 rpm. I'm thinking maybe I just need to accept for now that with the headlight on i'm only going to make 13.8 tops on the charging end of things. Could this be normal for this year GS?

[posplayr]

Yeah yeah, simple misunderstanding. I was quoting that though.

So after a few hours of tearing apart the headlamp basket and really looking into the harness at that end of the bike .. it seems like some kind of wiring modification was done after some sort of small electrical fire happened. There is one plastic socket that appears to be original and pretty melted. All the wires except one yellow with white stripe have been eliminated going through this socket towards the accessories. The side of this socket going to the main wiring harness run stays in tact, though. Also, there is one black with white stripe wire that is loose (terminated by itself) , and two brown (brown looking -- a bit color blind i am) wires that are loose and have plastic on the end terminating them together hanging inside the basket. These three wires (the black, and two brown) come from the same run as the headlamp wires. The headlamp socket (3 wires) is pretty melty, but still makes a good contact with the bulb (i assume because the lamp is working, and switching between high and low).

When on High beam, the voltage meeter gives me ok readings throughout the basic check. When on Low beam, the headlamp seems to draw a bit more voltage. Still, I am not seeing a solid 14.4 volts at 5,000 rpm. I'm thinking maybe I just need to accept for now that with the headlight on i'm only going to make 13.8 tops on the charging end of things. Could this be normal for this year GS?

Sorry for mis reading the post, I see now you were quoting; no wonder you were having such stellar charging.

On the other hand after looking at your numbers you are barely charging. You will need to continue testing to find out.

I would do the Revised Phase A tests to see what the voltage drops are and then Revised Phase B. Sorry but you are charging but without any other equipment to test with you are faced with a process of elimination.

Charging at low 13's is not normal either the load is too high or your stator is going out (your tests confirm it is not the battery).