Alternator connector very hot?? UPDATE!!!

[puremagic72]

Just noticed by accident as it touched my arm, the stator coil wiring connector is very hot, and as its white it has now gone dark brown!!

Even after only running the bike for a minute it gets very hot, is this normal??

Thanks,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Kickstart]

Hi

No it isn't usual for it to get hot enough to burn the plastic to brown.

With the ignition off disconnect the wires and clean the connectors as a first step.

All the best

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

[Gawain]

Not normal. A definate problem with the charging system- bad connection, fried reg/rec, bad battery etc

[puremagic72]

Thanks folks, will get it checked out!!

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Zeeky]

similar thing happened to me a couple o months ago, except mine burnt right through the conenctor and the bike stalled, battery got screwed... and my problem was because of a dodgy regulator...

i believe checking the voltage that reaches the battery with the bike turned on.. if its pretty high, (~18V!?) its possible ur regulator isnt doing its job...

good luck
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WoooHooooooooo!!!!!!!

[puremagic72]

Thanks Zeeky, i can do alot of stuff but its the 1st time i have had to check the battery or rectifier!!

Do both prongs on the muti-meter attach to the battery or just one positive and one earth?? Hopefully this dont soung too stupid!!

So if its high on the battery its the rectifier...and you mean turned on as in running or just ignition on?

Thanks,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Kickstart]

Hi

Assuming the connector is clean, next check is a voltage check over the battery.

Set the multimeter up for volts (DC), put the red lead on the battery +ve terminal and the black on the battery -ve terminal and check the voltage with the engine off. Should be around 12.5 volts (bit over, but not much). Start the engine and check again with the engine idling and then rev the engine. Idling the voltage should go up a bit and revved it should go up to about 14.5V. If the voltage goes up beyond that then it suggests the regulator / rectifier is shot. If the voltage doesn't go up then it could be the regulator / rectifier or the actual alternator (which you can check by checking the AC voltage into the regulator /rectifier but I have no specs for what is appropriate for your bike).

Most bikes use a combined regulator / rectifier, the rectifier turns AC voltages to DC, while the regulator turns the higher voltages down to around the 12V level (which means a bit higher in reality).

All the best

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

[puremagic72]

Thanks kickstart, i have a gsxr750 by the way(2000 model)

Even the generator cover is extemely hot!! You could light a fag on it, and thats only after a 2 minute ride home!

Thanks,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Pete.]

If the multi-pin plug has turned brown then the contacts are probably all black from overheating too. Personally I'd cut off the connector and join the wires firmly with a proper-sized chocolate block.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[puremagic72]

Typical...went out in shed to get the muti-meter out, took seat off, turned on the meter and even thats not working, opened it up and the connectors knackered on that!! DOH!!!!

Will have to wait till weekend now folks to get new one.

Some pics below of the problem, hopefully its just this!

Geri...thats what i was thinking of doing!! thanks for confirming its ok to do it!, thanks.

Thanks all,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Pete.]

Completely fubared mate.

https://www.made-in-china.com/image/2f0j00avYQNPtsVWqEM/Terminal-Block-U-W-.jpg
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[puremagic72]

Thanks Geri, do you think there is another reason for this to happen, or was it just age and build up of crud, hence making it worse then burning up!

Thanks,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Pete.]

At a guess I'd say a build-up of oxidisation on the terminals causing a high-resistance joint, which creates a voltage drop across the joint and generates heat. This heat speeds up the oxidisation process so things get rapidly worse.

The terminals are ruined, so replace them (don't try to connect blackened wires) and then check the charging voltage at the battery.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[puremagic72]

Thanks Geri..i'll have to buy a multi-meter 1st!! lol

But i'll cut & stick choc blocks on!

Thanks for all your help!

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[puremagic72]

Cant believe this, got flat tyre on way home! AARRGGHHHHH!!!!
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[puremagic72]

Ok, after chopping the old connecter off, put choc block on, been charging for 48 hrs now.

Battery when the bike is off is 12.90 volts
Battery when idle is 13.85 volts.
Battery when i have revved it too 5,000 rpm went down to 13.02

The alternator cover still got very hot just doing this quick test(not sure its supposed that quick)

So not sure if this is ok?

Thanks,

Baz
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Bikeless]

My mates R1 had the same problem which we tracked down to a bad earthing wire if that helps.His was also dropping the voltage when revved.

[puremagic72]

Thanks fireblade2102, another option to consider.

Forgot to mention i am running a spyball alarm which is renowned for sucking up juice alot!

Thanks,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Gawain]

Similar to my problem recently. I fixed it by wiring the reg/rec output direct to the battery cutting out the 'standard' charging circuitry, far more stable voltage at the battery.

[puremagic72]

Is that safe to do Gawain?

Thought the idea of the rr was to alter the voltage?

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Gawain]

[puremagic72]

So what does someone think of my voltage stats? Is this normal?

is the voltage supposed to drop a bit when revving to 5,000 rpm?

So to measure the r/r just unplug and change muti-meter to ohms and measure from r/r side?

Thanks,

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.

[Bikeless]

Kickstart already answered this for you,to go over it again,your voltage should rise a little when you rev the bike and you need the specs of your reg/rec to check any ohms readings.

[Kickstart]

Hi

The voltage almost certainly shouldn't drop like that when you rev it. Only bike I have had that happen to turned out to have a lose earth wire to the battery (so basically the same dodgy earth problem as fireblade2102 found).

All the best

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

[puremagic72]

Thanks Kickstart, i'll check it out!

Baz.
____________________
Make; cbr929cc blade Year; 2001
Gsxr 750 2000, alstare Corona, Current bike 1999 R6
(1) Kids in the back seat cause accidents; accidents in the back seat cause kids.