86 kawasaki vulcan 750 charging system

Question

i have a charge of.02 and .02 and .07 in the wires from the harnes that go to the stater ring. if i start the bike the stater ring puts out more charge and heats up the wires in the harnes that go to the regulator what are some things i can do to try and resolve this problem.

Answer 1

First off, check the voltage at the battery.  Set your multimeter for 20 volts DC, start the bike up and touch the probes to the battery terminals making sure to have the correct polarity.  It should show around 12V, speed the engine up to 4-5,000 rpm and check, it should show around 14.7V.  If not, then check the stator.

I've found that checking the resistance of the stator is much less reliable than checking the AC voltage output.  With the stator wiring harness unplugged and the bike running, set your multimeter to measure at least 100 volts AC.  Check each of the three pairs of wires using the meter leads as follows, right and middle wire, middle and left, right and left.  Check at idle and then speed the engine up a bit.  Each pair should show more or less the same voltage.  If there's much discrepancy, then the stator is shorted out.

If the stator checks out then the problem is likely either a wiring connection or the regulator rectifier.  Know that reg-recs are very reliable and be sure to check all wiring connections first for tightness and any corrosion.  Kawasaki Voyagers were bad about getting corrosion on the 3-way stator plugs and would melt them down.

Answer 2

The stator wires could be shorting internally or shorting on the engine case between the stator and the rectifier regulator.Have the rectifier checked for proper function of the diode trio.Electricity should only flow one direction.Use the diode test section on a volt meter.If bad replace.

Answer 3

It sounds to me like your rectifier has went out.