er5, reg.rec problem, can any of you chaps provide me with..

[shleppy]

a solution:

heres the problem - the kawasaki er5 has a problem, the reg.rec blows, but thats not all, when it goes, and this seems to be a common problem on all years of er5, it bypass' fuses and blows nearly all the electrics, the only way to prevent this at the moment is to spot the signs of it going before it goes.

becuase its the reg.rec im not sure if i could just solder in a fuse or resistor in there, cause i still want it to perform its task, but there must be a solution to this, why dont other bikes have this problem?

aparently the reg.rec malfunctions in the first place becuase of its positioning, under the bike behind the wheel, so it gets covered in road dirt, and then overheats ect, so ive thought about moving it but id really prefer to have the comfort knowing i have some protection for my electrics.

ill post up my bikes haynes circuit diagram and hope one of the more gifted electrically minded people can give me some good ideas.

[stinkwheel]

Never heard of this as a problem.

They DO have a problem with corrosion on the wire running from main fuse to the bikes live feed (usually white, as on the attached diagram). It's gone on all three 500 twins I've owned

This causes a bad connection and essentially stops the battery both charging and feeding the electrics. I could see how this intermittantly making and breaking contact could confuse the hell out of the reg/rec and eventually cook it.

The reg/rec feeds in after the main fuse for some reason.

I would imagine fitting an additional 30A fuse where I've marked it in yellow on the attached diagram would protect the loom in the case of the reg/rec spiking the output too high.

If you're having trouble with it eating reg/recs though, check that wire at both ends for signs of corrosion, especially inside the main fuse holder attached to the starter solenoid.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[hmmmnz]

as above.
if you still have a problem.
then move the little bastard, contrary to popular belief, motorcycle manufactures don't know it all. place it in a position not too far from the alternator with plenty of air flow around it and away from salt filled muddy road slag.
have fun
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the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[Ade]

or get a hugger

Does seem to be a fairly common problem on the Er-5s, thankfully mine is ok (than agin, with only 6k on the clock, you'd think so )

Ade

[davidimurray]

Yeah, it's fairly common on the ER5s - but only if you rev them a lot! My brother in law has had dozens and dozens of them and only ever had 1 reg/rec fail (training school).

Putting a fuse in may help but I thought it was the voltage that was the problem. When the reg goes it tends to start spitting out silly voltages - when mine went it gave 18V at idle that rose with the revs! I could smell the battery boiling!

Once the voltage gets high enough I think it then kills the reg on the rev counter circuit and blows the bulbs.

[kawakid]

I've had a regulator go on my ER5 earlier this year.

I noticed after light bulbs blown after just swapping them.

You need a multimeter, to test , I think mine went up to 19v when
it went.

I had lots of problems when I ordered a replacement, because it came with totally different connector than what was on the ER5.

See this post https://www.bikechatforums.com/viewtopic.php?t=105520&highlight=

Basically you need to make sure they supply you with the correct connector, or its a major arse. ie they expected me to cut in to the loom and cut the terminal block of the new rectifier (yeahh right, what if it doesn't work and they didn't supply me with a wiring diagram).

Make sure you get the right connector.

The other issue I had was bolts broke as I tried to take it out and I had to take it to a garage to remove the bolts. (Cost me £20 they used some chemical to get them out).

Remember a fuse only protects you about amps not voltage. So its not going to do anything to help with a rectifier fault.
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I've a twin and a 4.

[shleppy]

after looking for voltage protection, there was a circuit i found which basically shorted out itself when a high voltage came along, and i also found another alternative, has anyone used a voltage dependant resistor before?

i have now realised a fuse wouldnt do anything.

[bugsy46]

well thats the job of the reg rec, a series of diodes and gates to short too high voltage to earth to mantain a safe charge rate to the battery. Check the wire that runs from the reg rec to the battery, if this is corroded then the power will back up and blow the reg rec. Stinkwheel quote me on this matey, iv seen it on blackbirds
____________________
Laura - "And where did looks come into this and bugsy leave steven alone. You are not gods gift to women you may think you are but you're not."
Keith - "All the best"

[sickpup]

[bugsy46]

Ive never heard such shit in all my life.

I shall give you a lesson in regulator rectifiers my friend

The reason for a reg/rec having fins is to disipate heat. This is because they use semiconductors.

SINGLE PHASE HALF WAVE RECTIFICATION

Uses a diode to convert AC to DC. Outputs positive half cycles. Used on small bikes with low load

INTERNAL VOLTAGE REGULATION

Current from the coil is regulated through 1 diode, and then fed to the battery. The voltage is regulated by the reg circuit and an SCR. as the RPM increases, the alternator output does aswell and is rectified by another diode, this current then goes to a zenor diode. The current flows in the normal direction but not reverse until a certain voltage is applied. When it has, the ZD conducts it in the reverse, thus turning the SCR on. When it turns on, the output from the alternator is shorted to ground through the SCR, this obviously explains why a battery over charges if there is a bad earth.

Now, sickpup, go back to your haynes manual and when you know something about charging systems come back and pour advice to people who need it. Your post had me in stitches because it confirms you know jack shit.

Night x
____________________
Laura - "And where did looks come into this and bugsy leave steven alone. You are not gods gift to women you may think you are but you're not."
Keith - "All the best"

[sickpup]