ER5 Regulator/Rectifier

[smudgetactica...]

Have just read all the posts for R/Rs and many thanks to all posters for my now anal knowledge of said items, I have two more questions regarding these black magic boxes.... if my R/R is tits , will it cause my 30 amper to blow? Did a fault finding method of pulling all plugs on my ER5, cleaned all contacts and re-introduced them to the gang, to find out what was causing the big boy to blow, R/R was was the bad boy. New one inbound from the resourceful e-bay, though now slightly worried about its compatability as its from a GPZ500, will I need to do any rewiring or is my paranoya unjustified.

Yours

Running out of 30A fuses!! Smudge

[finpos]

"Good Chance"

The output of the generator is unlikely to blow the fuse, so the fuse would blow without the engine running. is that right?

Assuming your regulator has 5 wires:
3 are the same or very similar colours (possibly yellow?)
one red wire
one other wire (possibly black?)

For the fuse to blow from battery current:

Either: One of the components in the reg/rec will have failed into closed circuit to earth. In this case, you should find a dead short between the connectors for red and black on the regulator.

Or: There's a problem with your altenator. This may mean that the reg/rec may or may not have failed. You need to check for a dead short to earth between any of the yellow WIRES and earth.

Balance of probabilities is the first option.

If your new regulator does not plug right in, some wiring butchery should sort it.

finpos.

[smudgetactica...]

Blimey Finpos, that was quick, didn't even get to drink a cup of tea!!!

Yes you are correct that with no ignition key inserted it blows the 30A.
Just checked across the Black and Red leads, with no dead short ,
My R/R isnt the most convincing looking one (see attach) as it appears to have been changed in the past and bodged to work, hence my first suspisious eyebrow raise when found...mmm new altenator..better start trolling e-bay again, though just got to check the yellows for shorts to earth.

Many, many thanks for your V quick responce.

Regards

Smudge

Will give you the or on results, cheers again.

[davidimurray]

Hi Smudge

Have you got a the Kawasaki service manual ? This gives a test procedure for the R/R and a very rough idea of the resistances across connections.

Cheers

Dave

[finpos]

That's by far not the worst bodgery I have seen. Bloke's gone as far as to use heat-shrink crimps, shame he didn't shrink 'em!

Don't worry at this stage about any measurements you are getting off the regulator itself. It's full of semiconductors and so it's a bit tricky to actually fathom. What really wanted you to check is that you don't have a short in the altenator - this is really pretty unlikly, but not impossible.

The picture shows me you have a six wire regulator, the three yellow wires are the altenator windings, the red is the output, black should be earth and blue should be "sense".

You can do further checks on the wiring: I'm guessing colours here, the manual will be a better source of info!

To check the wiring, check for dead shorts on the disconnected connector (the wiring loom, not the regulator!) between the red, black and blue wires. If blue to red is dead short, don't worry about it. anything else may warrent further investigation.

Also check to see if you have a dead short between blue and black on the regulator itself. When checking anything on the regulator, pay attention to your red/black test leads - make sure they are the right way round (I assmume you know what I'm talking about!)

finpos,

[smudgetactica...]

Cheers to Finpos!!!

Sorry for delay in reply, had to work the Bank Holiday Had today off to sort out my R/R and fortune must have been smiling as I rewired my GPZ R/R and it worked!!! , only 1 tiny prob as my oil pressure and coolant temp warning indicators are permanently on, but no biggy, will wait for ebay to throw up an ER5 R/R got a Thundercat to play with, its got to get dirty at least once a year!!!

Many thanks again to you Finpos and you Dave.
I will toast you with my scran tonight!!

Regards

Smudge