generator preblem on my zxr 400

[notorious]

hi lads im new to this so bear with me,i have a zxr 400 and am having a problem with the battery not charging,i have bought a new rectifier and still no luck so i figure its the generator,i have one on order and was wondering if i would be better off getting it fitted in a garage or are they handy enough to do yourself any solutions are welcome because my head is melted with this one cheers lads thanks for taking the time

[neatbik]

Easy peasy to fit yourself mate

Disconnect the generator multi-plug coming from the generater cover.
Undo the generater case bolts, carefully pull it off the bike. You will lose a bit of oil - either catch it in a clean container and put it back after, or drain all the oil first.

You will feel some resistance when you remove the cover, this is the stator and rotor's magnet effect - just keep pulling.

When you have got the cover off remove the old knackered stator (will more than likely be just 3 bolts) and fit the new one - be carefull though, you dont want to damage the 'varnish' on the copper windings.

Then refit it, connect up multiplug using a bit of dialectric grease, top up your oil and your done.

Its also worthwhile inspecting all of the wiring relating to the charging circuit, it has been known for multiplugs to burn up after generater problems.



It may be worth doing some simple electrical tests before hand though - do you have a multimeter handy?

[notorious]

beatnck2 thats a great help im after putting alot of time respraying and doing up this bike cant wait to take her without having to bring a spare battery haha,i have a multymetre,im not sure on what exactly i should be testing again thans for helping mate

[neatbik]

You need to set it to resistance setting (ohms) and test each of the 3 wires in pairs with the ignition off. (disconnect the multi plug first)

You are looking for continuity between all of the wires.
Then measure from each of the 3 wires to a 'ground' point on the bike i.e engine case, battery earth point.

There should be no continuity there - if there is it means the stator coil has ground out to earth.


If all is well, next (with the multiplug still disconnected) fire up the bike, set your multimeter to read AC and measure the 3 wires in 'pairs' again.
Be careful here though - dont let the multimeter pins touch each other and be certain you have set it to AC.
At idle you should be getting around 20VAC, at 5000rpm you should be getting about 60VAC.

Dont worry too much about the specific voltage, as long as its the same between 'each pair' and rises nicely with the revs its all good.


Just be careful when measuring the AC voltage though, 60VAC can sting a bit.


If this all reads good then chances are the generater is ok, but its worth whipping it out and giving it a visual check.

I recently had to replace mine, it looked like this -
https://i158.photobucket.com/albums/t94/Epyon_au/P8290004.jpg

Feel free to pm me if i havent made sense mate, had a late one last night

[notorious]

thats great beatnck,im still waiting on the part from england but il let u know how i get on ,i imagined that the generater would be fixed to the engine block,judging by your foto its actually fixed to the casing itself,il keep you posted cheers again man apperciate the help

[neatbik]

No worries mate

[notorious]

hi beatnck2 i got the the part today il be fitting it on saturday il also be replacing the rectifier aswell,do you think this will solve the the charging problem or is there something else i should look out for,from what i heard from friends this should do the job thanks again you have been a great help

[unitybiker]

most charging problems are rectifier based genny coils are usually the last thing to break .The rectifier takes the ac voltage and converts it to dc ,using a voltage limiter to set it at about 13,5 volts ,some bikes incorperate the regulator in the cdi ignition unit. Since you will be replacing the lot ,if it still dos'nt charge then check for bad connecter plugs and pins

[notorious]

hi lads im back again,NOW,ive changed the rectifier and generator,checked all the plugs for corosion and still the battery is still not charging ,my head is done in at this stage ,have you lads any other ideas what i can try to sort out this problem cheers

[alun111]

I'd have your battery checked out - IF as you say all connections are clean and tight. Before you whip the battery off check that the terminals are tight - if they're not that could be your problem.
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[notorious]

all that is fine double checked everything could there be any other problem

[alun111]

Have you measured your alternator output? Did you buy the reg/rec brand new?
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[notorious]

i bought the reg- rec and generatir brand new,i think i might have messed it up myself ,when i took off the caseing for the geny and took out the old one there is a rubber seal that the new geny wires had to be pushed through,so i snipped them pushed them through and just twisted them back together and taped them,i think il have to crimp and solder them,what do you think would this make me loose the current.I KNOW IM A FOOL

[alun111]

[notorious]

just after crimping the wires still no joy,im ready to through the towel in man unless there is nothing im missing please help me please

[alun111]

you need to pull apart the alternator/reg rec block connectors and check the pins for cleanliness and good contact. If they're corroded (green/white) then clean them up.... if any of the pins are burnt out you'll need to replace them.

Have you tested your alternator output? If it's outputing then check the block connector and the reg/rec and it's connections. Also make sure your battery terminals are tight and clean.

What;s your battery actually showing when the bike's running?
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[notorious]

the battery is showing 12.8 when not running and when i start it she is dropping in volts all connecters are and cleaned i think i have to bite the bullet and drop it in to a bike shop

[alun111]

the voltage is dropping whilst your finger's on the button or when the bike is running?

What have you done to "check" your battery? Just because it has a healthy voltage it doesn't mean it's accepting a charge.
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[notorious]

ive charge the battery fully,while the bike was off the road the battery was staying fully charged,i not well up there with a multymetre im only new to this game electrics are not my best subject sorry man

[alun111]

How old is the battery and was it stood for a while before you bought the bike?
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[notorious]

i dont know how old it is man and again not sure if it was lying up before i bought it,i only have it about 3 months,starting to regret clapping eyes on it at all

[neatbik]

Whereabouts are you mate? One of us might be local to you and willing to look at it

[notorious]

i live in celbridge in kildare would be great if u could

[notorious]

sorry i think i broke the the thread rules there

[Bikeless]

Check all the earthing points on the bike,went through this with my mates R1,new reg/recs,batteries,the lot,ended up being a faulty earth from the starter motor.