R1 Electrics

[Korn]

5 headlight bulbs in 2 months, this is not on

Am I right in thinking it could be the rectifier? I noticed today that it gets incredibly hot, so much so that it's melted some of the plastic in its plug. I'm going to attach a small 12v fan to it tomorrow, but what I want to know is could the heat alone be causing the bulb-blowage or does it sound like the rectifier needs replacing? Or have I missed the plot completely?

Everything else electrical I have no complaints with, it's charging fine and the battery seems to hold plenty of juice - it's just it keeps eating these bloody bulbs
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3516 Miles, 11 Countries

[william]

This is a reply I got to my posting about my battery on an R1 forum:

"definitely know what the problem is; sounds like your regulator burnt out.
Take off your gas tank and look at your regulator. Unscrew it from the frame and check out the wires. One of the wires is probably burnt. Happened to my R1 twice already and finally know what to do to remedy this. You have to install a fan used on CPU's on top of the regulator to cool it down. Clean your contact points on the regulator with some kind of non-grease cleaner. Hopefully your female connectors aren't too badly burnt out already bro; you might have to do some wire splicing or even worse have to invest in a whole electrical wiring harness kit that can cost from 50-300 dollars depending where you buy it from.
Check that and get back to me and I'll talk you step by step how to remedy the problem if your regulator is the problem. i am 100% sure it is the problem."

Sounds like you are on the right lines but maybe the regulator has already gone hence the blowing bulbs.ie >14.5V
Quote again!

"Install known good battery into bike and start engine. After warm-up, bring engine speed up to 5000 rpm and measure the battery voltage at the same time. The voltage should be about 14~14.5 volts. If the voltage is greater than 15, the problem is most likely the rectifier/regulator. If the voltage is less than 13.5, then it’s either the alternator (stator coil) or the rectifier/regulator, or possibly even both."



William

[Korn]

Ahh, yes. Looks well toasted

Time to repair the crispy contact and stick a fan on it methinks, then see if it goes through any more bulbs.
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3516 Miles, 11 Countries

[Kickstart]

Hi

Normally a regulator blows in style, but it is possible for them to allow the bike to overcharge. Stick a voltmeter over the battery and rev the engine. Suspect it might well go over 15V.

As well as the fan it might be worth trying to duct cold air onto it, or maybe just shield it from hot air from the engine.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Kickstart]

Hi

Eeek. Yep, looks like something is putting out too much current.

Check the contacts are clean though. Also ensure that the there is nothing putting a large load on the battery (eg, alarm almost killing the battery so that it has to try like mad to charge it when started).

Bulbs die from old age (not that yours have a chance), vibration and from too much power going through them. Given that I think you are probably right that the regulator has gone.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Korn]

Right, cleaned up the crispy contact this morning and plugged the reg/rec back in then tested the battery with the bike off, 12v. Fired the bike up, 14v. Let it warm up and gave it some abuse, still 14v.

Took it to work - about a 40 minute journey - with the headlights on, then turned it off and did the test again. Off, 12v. Running, 13v. Much revvage, still 13v. The whole bike was roasting hot and the radiator fan had kicked in, dunno if that accounts for the drop or not?

Couldn't get it to spike though, this is a good sign no?
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3516 Miles, 11 Countries

[Claud 14.7 to 1]

if it helps, the reg/rec not only manages the power coing back to the battery, but controlls the lights as well. sorry about but not being technical enough, but i forgot what does what, was a time ago.

i had a charging problem on my honda cbr400. lights were ok. turns out the reg/rec went. my symptoms were; it would get very hot within a few seconds. Although they do get hot by nature they should not get that hot so quickely and def not fry. i upgraded to a heavy duty unit, without a fan but with many cooling fins i also used some silicon cooling compound to diccipate the heat to the bikes frame, the same as used for cpu/heatsink applications.

id say the part of your reg/rec COULD have gone, seeing as its burnt.

also check grounds for the lighting stystem. you could check for continuity along the wiring. check for corroded contacts.points along the whole wiring (if its not too much trouble). Could just be a dodgey ground...

my bike is old and i found that some contacts were very badly corroded. cleaned them up with contace cleaner/file.

the other way i tested the unit (for charging) was to warm up engine and put all lights on ie brake, indicators, headlights then check the power going into the batt, at about 5000rpm. this puts the bike under real life conditions. ive got about 13.2v which is fine...(with the new reg/rec fitted) old one was more like 11v

get a haynes manual they are very good for advice and repairs etc!

good luck

just hope it nothing worst like stator windings/stator etc. shouldnt be though

[Claud 14.7 to 1]

ps haynes can give you the requirements to test your reg/rec. got a multimeter?

def get a haynes, first thing i bought!

[Korn]

Haynes manual says "Consult Yamaha for regulator/rectifier testing procedure". Yamaha manual says "You can't test it, buy a new one"
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3516 Miles, 11 Countries

[Claud 14.7 to 1]

so you say it still works fine even though it appeared burnt. and the problem is intermittant, ie the bulbs blow occasionally. there is no other problems?

know anyone that has the same r1, you can swap them over and test the reg/recs.

btw are you sure you are using the right wattage bulbs? mines a jap bike so although the bulbs appear to look like 472s they need a lower wattage bulb. higher ones apparently cause my bike problems. check that out. the standard 472 are somthing like 55/60 the ones i need are more like 35/50. may be worth a try. That what i was told could be the problem when i was investigating on mine.

checked the gounds/contacts?

eletrics are bitches, especially intermittant ones. my bike simply cut out randomly when i was riding. the batt was so flat after it cut out, it didnt even turn over .

[Claud 14.7 to 1]

not using aftermarket, high power bulbs are you?

[Korn]

One trip to Maplin's later and I've rigged the rectifier with it's own fan. It's a bit silly of Yamaha to mount it to the plastic battery tray instead of the frame where it could at least dissipate some heat

Anyway, put new bulbs in and took it for a ride - none blown. So far so good.
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3516 Miles, 11 Countries

[Claud 14.7 to 1]

[Demonic69]

Korn at least yours has fins to help. Most honda ones are just plain black with no form of heat dissipation at all
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Back on a Blade. Just feels so right.

[Korn]

Honda electrics are a lot better IMHO. I never had any problems with the NSR/RVF/VTR but all my SR's & the R1 have had gremlins.
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3516 Miles, 11 Countries

[Claud 14.7 to 1]

[william]

I was talking to someone earlier who has gone thru two regulators in two years on a 98 R1.

I am tempted to knock up six short sacrificial extension wires with appropriate connectors just in case it happens to me and fries the proper connector (which seems common as is confirmed by Korn's pictures).

William

[william]

Korn,

You might want to check this out if you do need a new regulator now - or in the future.

I am tempted and I havn't got a problem YET.

https://www.electrexworld.co.uk/erol.html#1x0&&

William