ER5 rec/reg advice please

[Ebbs73]

Hello people

I'd just like a few pointers from you .

I have a Kawasaki er5 , I use it for all my dirty hardworking tours , 3 elephant rally's , dragon , and Stella alpina rally .
She works hard and has always been very good to me .

After this years elephant she needed love , I've gone all the normals , chain , sprockets , bearings and seals , fork seals etc .
I noticed the rev counter die as have read it's a sign of the reg/rec , my battery has gone dead a few times so I bought a MOSFET er5 , straight plug in .
All swooped over , easy .

After a run yesterday the battery was flat and I had to bump her , got home and started testing , I'm only getting 11.8 volts ish even when revving it , its the same voltage with the rec disconnected so I take it it's the battery giving that after a charge ,
I've got the book so I've tested the stator and I have 60 v on each yellow , tested the old rec and the readings are about right , so was it faulty ??
I haven't got the specs for the new one so I've emailed the company for them .

The only thing I'm worried about , I had the new one plugged in trying to test it hanging from the bike and after 2/3 mins running Christ it got hot .
Is this a sign it's faulty ?

Any ideas or where I'm going wrong would be appreciated

Thank you

Chris

[Ebbs73]

Just to say , I did search and there's loads of info on it but not regarding the heat .

Thanks

[ThatDippyTwat]

They're meant to get hot, and they need to use the frame as a heatsink.

By hanging it from the bike, you lose the ability to rid it of heat by conducting it. For best results, mount to frame with a *thin* smear of heatsink compound.
____________________
'98 VFR800 (touring) - '12 VFR800 Crosrunner (Commuting) - '01 KDX220 (Big Green Antisocial Machine)

[Ebbs73]

Yeah that makes sense , I took it off just to aid testing .

Either one doesn't have an output at all .

Im losing the will to live now ,



Thank you

[andy_uk]

Here's a pretty good (in my opinion) reg/rec testing flow-chart.

Hope it helps.
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Aprilia Classic 125, GS500E, ER5-A1, ER5-C4, ER6 & an XJ6 project frame...

[Ebbs73]

Thank you , I'll have a nose .

I've followed the ones in the Haynes manual , not sure if it's me or the book that's lost !

[Robby]

Who did you get the reg/rec from? If it was suspiciously cheap, it may not be a MOSFET.

The symptoms sound like classic reg/rec failure. First time I've heard of a MOSFET failing, hence the interest in its origins.

[stinkwheel]

Check under the LHS engine cover early doors. Just in case the alternator rotor has bombed. I'm not sure about yours but other EX500 variants had a habit of dropping poorly glued magnets off at high rpm. Mayhem ensues.
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“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.

[Ebbs73]

I bought the rec/reg direct from them so all good .

I've put it back on with some heat paste , redone the connector , brand new battery ...

Still not charging , cleaned all the connectors and grease them .

I have the corrected voltage going in on all 3 yellows from the stator , the reg gets hot so I guess it's doing something .

Would I get 13.8 v ish on the red wire from the reg , what does the white do ?
I've been looking at the wiring diagram but it's starting to blur ?

I'll nose at the dropped magnet .

Thanks for the help and susgestions .

Chris

[Ebbs73]

May I pick your brains again .


I've been over every connector and cleaned them , I appear to be getting a charge but .

Form he diagram I have 2 wires the wrong way round and it charges ( white and brown )

I'm think the brown is the 12 v form the ignition and the white the charge .

If I have them as the book it doesn't charge , if I put them the other way round it charges but when you turn the key off it keeps running !
It will turn off with the main switch .

I'm losing the will to live .

Thank you