Topic: Fuse box

[Canadian]

Here I am, yet again with a question regarding fuses.

In short:
°Main fuse keeps on blowing, nothing changed to the bike, been driving like this for a year
°Checked the wiring, no bad ground, no wire touching another one
°Battery doesn't really charge anymore, only reads max of 13 volts when running
°When she's cold I can drive up to 10 minutes, seems something is getting too hot & fuse blows
°Tried a new regulator , keeps blowing

Any tricks/ideas what might cause this ? No clue anymore , maybe rectifire.. ?

Thanks guys,
Wannes (Belgium, Europe)

[Jerry Rxman Griffin aka MuthaF'er]

Take a look at your ignition switch.

[Canadian]

Sorry forgot to mention.

the box was corroded & changed it to modern fusebox, ALL works fine

What makes you think of the ignition switch ?

Thx!

[Canadian]

You are contract these are in contrast to each other. Indeed I've changed this to a modern one with modern fuses. No short or loose connection here.

It is an aftermarket ignition switch. But this one goes for 1 year now so don't understand why all of a sudden it would go ... anyway I'll check

Thanks!

[Canadian]

Hi there,

Thanks for replying. I must say i'm good at welding, mocking up stuff, making fibre seat etc but electronics is my worst nightmare.

I do have a multimeter. How do I read if this one is broken or not ? Have 3 stands (off / on / on  + lights).

When I start driving I can do about 10mins, then all of a sudden the fuse blows. The battery only reading max 13.2 volts or so worries me as well (when revving at 6000rpm).

Ofcoure something's heated too much & then I have to wait 30mins to pop another fuse in , to drive home...

Thanks again guys.

[Canadian]

Sound a bit Chinese but i'll manage, good explanation thx!

 I'll have a look tonight.

I'll find the 8pin plastic connector. Here I need to check the Ohms on Yellow Yellow Yellow and th White Green whires?

So put my meter on the yellow and each time check with white & green correct? What is 'too high' ?

Suppose my ignition (key) has to be ON ?

Brgds
Wannes

[Canadian]

Think i found it!

Measured My rectifier and :

Black of multimeter on green of rectifier
To 3 yellows: ALL around 0.5v , perfect

Black of multimeter on red of rectifier
Tob3 yellows: nothing! Nothing AT ALL

The rectifier was mounted in My seat so not much cooling.

Will Search a New one & advise outcome

[Jerry Rxman Griffin aka MuthaF'er]

The ignition switch carries an awful lot of current! Great place for a loss.

Rectifier rectifies the AC current to DC by eliminating one of the alternating legs thus DC. Not sure about your test?

[Canadian]

Multimeter was broken !

Rectifier was good.. Anyway Changed regulator (was also good) en rectifier with New ones, that Come Off a running bike here. MeSured with a good multimeter & they are ok.

Ignition on hit My starter, Goes over a couple of times, fuse blows. First time this happens.

Pop another one in, starts & let it turn idle for 5mins, ALL ok. Measured volts on battery max 13.5 V with almost Full Throthle.

Want to drive, 200 meters and BAMMMM, done, again.

Immediately checked & tried to touch the rectifier, Can bearely touch it...


So Moving On.... Ignition coils shortage or something ? NO wire is hitting another one, ALL already checked!

Thx in advance!

Wannes

[Canadian]

Oh & changed the ignition lock to the original one

[madmtnmotors]

Takes me about two weeks to clean every switch and connector in the harness. As mentioned, focus on the high amp connectors first:

http://forums.sohc4.net/index.php/topic,137351.msg1549191.html#msg1549191

http://forums.sohc4.net/index.php/topic,148188.msg1688494.html#msg1688494

[madmtnmotors]

Don't forget the alternator connectors under the front sprocket cover. Those connections tend to suffer the most...

[Canadian]

Checked alternator connector, clean & good connection.

Pls advise on the Next step, dumb regarding electronic etc !

Thx

[madmtnmotors]

Checked alternator connector, clean & good connection.

Pls advise on the Next step, dumb regarding electronic etc !

Thx

Both sets of alternator connections? There is one multi-connector block that is above the rear of the engine, and then there are five individual bullet connectors tucked in behind the transmission cover underneath the front sprocket cover. Those five individual bullet connectors (3-yellow, 1-green, 1-white) tend to be the connectors that suffer the most...

[Canadian]

2 rectifiers are now broken, after this fuse blew

Next step? Measuring ohms On...?

[Canadian]

Anyone ?

[madmtnmotors]

2 rectifiers are now broken

And what leads you to this conclusion?

After this fuse blew

Which fuse?

Next step? Measuring ohms On...?

Everything.

[Canadian]

Measured the rectifiers ? The ohms were good First, now not any longer


The Main fuse

Everything... Pls specify on how to read/analyse My spools etc

[madmtnmotors]

Measured the rectifiers ? The ohms were good First, now not any longer


The Main fuse

The rectifier is a set of diodes. Current can only flow one direction through the rectifier. Did you check voltage both directions? Your ohmmeter has to push a small amount of voltage (from the battery inside the meter) in order to measure ohms. You will also get false ohm readings if your meter battery is dead.

Everything... Pls specify on how to read/analyse My spools etc

Check my signature for link(s) to charging system diagnosis, as well as electrical system troubleshooting:

http://forums.sohc4.net/index.php/topic,137351.msg1549191.html#msg1549191
http://forums.sohc4.net/index.php/topic,148188.msg1688494.html#msg1688494
http://forums.sohc4.net/index.php/topic,139544.msg1579364.html#msg1579364
http://forums.sohc4.net/index.php/topic,1012.msg8345.html#msg8345

[Canadian]

Thanks for above,

This is pretty much My problem:

http://www.xs650.com/forum/showthread.php?t=19916

Can someone tell me how to measure my alternator rotor , or how to dismount it?

Sorry for my English my mothertongue is Dutch.

The link i gave Seems 200% my problem. Mine does weird stuff around 4000rpm AS Well !

[madmtnmotors]

What bike (make, model and year) are we even talking about?

[Canadian]

So sorry,

Honda CB550F 1977.



If I read everything in the link I've posted previously this seems 200% my problem. And frankly can't think of anything else anymore.

As told, no wires are touching somewhere, all carefully checked.

I measured the 1st rectifier and it was broken (putting black of multimeter on the red on & red of the multimeter on every yellow one, you need to read 0.5 to 0.6 ohms).
New one that I measured, all good!

Started, main fuse blew, rectifier really hot, measured and broken as well.

Now just would like to know how to measure my ohms on the alternator widings etc & how to get it off the bike...

Thanks in advance!

Brgds,
Wannes

[Canadian]

Hi Calj,


Yes stock rectifier & regulator. Altered the stock wiring harness, What do you mean with altered? Sorry as told native tongue Dutch...

Ok pics to follow tonight.

Thx,
Wannes

[Canadian]

No i havent, mean i don't Use winkers etc but are all carefully taped. Been driving like this for over a year now.

All wired doublechecked, none Can make contact, is broken,...

[Canadian]

Hi guys,

Measured field coil resistance, i read 4.0

Manual says 4.9 +- 10%

Guessing this is broken?

[madmtnmotors]

Hi guys,

Measured field coil resistance, i read 4.0

Manual says 4.9 +- 10%

Guessing this is broken?

The field coil is pretty foolproof, it's just a hunk of iron with wire wrapped around it creating an electro-magnet. When energized it generates the magnetic field that makes the alternator work. This is the part that requires your battery to be fully charged in order for the alternator to function. I do not know how this component could be the source of your problem. You can test it by putting power to it (white and green from the alternator harness) and see if a wrench (or other bit of iron) will stick to the alternator cover.

The stator coil is what generates the charging current and creates the most load. I suggest you follow the procedure for testing the AC output of the stator coil. I would disconnect the rectifier for this test so you don't fry another one (you have to disconnect the yellow wires to test the AC output of the stator anyway).

[Canadian]

Thanks,

When i disconnect the yellow ones from the stator coil & measure i read zero...

Needs to be 0.35 ohm according to manual...

How much do i need to measure when running?

Wannes