Topic: battery test to determine why not charging

[scottly]

At this point, my guess is that your charging system is functioning properly, but the load is greater than normal. The fact that the headlight stays on, even with the fuse pulled is a red flag! If both the high and low beams were on at the same time it would draw an additional 40-55 watts, depending on the bulb type. I would try unplugging the headlight, and do the engine running voltage test again.

[evinrude7]

gotcha, the headlight does function properly moving between low and hi beam.  one thing worth mentioning is the fuse panel is not in the greatest shape.  one tab on one side for the headlight fuse has broken off and the tab below the missing one is loose.  the fuse will stay in there with a little tape and seem to make a connection.  i wonder if on the back of the panel somehow the connection is being made regardless of the fuse because it also seems that the PO put 14 amp fuses in both the headlight and tail light spot.  maybe it fused itself permanently.  i'll pull it off and get a look. 

[Jimray23]

I think before u can really fix ur issues you will need a new fuse block

Jimmy
1979 kz1000 ltd mkii
     dyna s ignition, dyna 3 ohm coils, solid copper core plugs, full rewire.

[evinrude7]

i agree jim.  i'll order one tonight. 

so i throttled the thing up to 5000 rpm CALJ and i got 13.4 volts.  i'll look for the next thing to check on the flow chart. 

took it for a 20 minute ride just now.  ran it through all the gears.  my recorded voltage with key off before i left was 12.5 volts.  when i returned key off 12.4 volts.  ?

[calj737]

so i throttled the thing up to 5000 rpm CALJ and i got 13.4 volts.  i'll look for the next thing to check on the flow chart.

13.4 at 5k is lower than it should be. Can you please post your voltage from the bike, running at the following RPMs:

Idle voltage:
2,000
3,000
5,000
6,000

It appears your bike is charging, but perhaps not "just right". It could be down to the aftermarket Regulator needing a bit more tweak. It may also very well be as Scottly proposed, your components are drawing more than stock. Let's do this test above and see what we get.

[evinrude7]

2000 - 12 V
3000 - 12.4 V
5000 - 12.5 V
6000 - 12.6 V

just a heads up.  as i was performing the test and kind of readjusting my DMM i noticed a reading at 10.X.  after i messed w the throttle a bit and then set my leads again i started to get readings back closer to 12.  but there was definitely a drop some place so voltage is not staying well above 12 at all times.  the leads were solidly in contact when i got the 10.X reading.  something like 10.7 i recall. 

[scottly]

You had up to 14.1V before, and now the best is 12.6V? Sounds like you may have an intermittent problem with the charging system. Since the fuse box has known issues, you might as well replace it before further testing. Consider a blade-type fuse box, rather than the stock glass type; the fuses are easier to find, and seem to be less trouble prone. I believe Hondaman makes a plug-and-play blade box.   

[calj737]

So now its time to detail to us, what non-stock components you have like the head light wattages, anything else the that you know of, and we start to determine finally whether the Regulator is at fault, or can be/should be adjusted.

You can also proceed with the flowchart in the interim since you now have voltage readings. You should be reading the resistance of the generator and switch your meter to the lowest Ohms-range. Measure the resistance between the WHITE and GREEN wires where they exit the stator cover.

[evinrude7]

thanks scott.  yeah it WAS up around 14.4.  whacky.  any downside to the blade type fuse box? 

calj, i'm a total newbie at this.  few months in.  bought the bike from a customer.  it was sitting on the side of his house for over 2 years with no side covers, a flat rear tire, gummed up carbs, dead battery, no seat cover, and a locked front brake.  i don't think he had much memory of what he did to the bike or the PO before him.  i couldn't begin to tell you what's not stock beyond the obvious that i have noticed.  here's the list i have so far. 

regulator is obviously not stock. 
tail light was not stock bulb it was led and i changed it out for a sylvania oem type
blinker relay was not stock or working so i bought a replica from vintage750
replacement battery is not stock but rated for the bike
rear left turn signal is not connected.  i have repaired the bulb socket but not connected
starter button is missing and wiring not present inside switch box right hand control

otherwise the wiring harness all looks stock but i'm almost positive there are some homemade connections where some of the bullet connections should be, such as the left rear signal light. 

i'm going to order another fuse box because mine is definitely compromised. 

[scottly]

thanks scott.  yeah it WAS up around 14.4.  whacky.  any downside to the blade type fuse box? 

No, not if you get a true plug-and-play fuse box. I wouldn't replace an adjustable solid-state regulator with a stock mechanical regulator, either.  

[evinrude7]

gotcha so keep what i have on the regulator or find a new one that is similar? 

about to order a blade type box from hondaman.  would like to support him.

[evinrude7]

scott,  i pulled the headlight.  it's a GE 6014


Amperage      3.91/4.69 A
Average Life      200/320 hr.
Base Style      3 Lugs
Bulb      Par 56
Candle Power      89 MSCP
Color      Clear
Diameter      7 in.
Filament      C-6
Lamp Type      Sealed Beam Lamp
Length      5 in.
Lumens      1120 lm
System of Measurement      Fractional
Trade Number      6014
Voltage      12.8 V
Watts      50/60 W

[evinrude7]

are the head lights specs above acceptable or pulling too much power? 

[calj737]

are the head lights specs above acceptable or pulling too much power?

Fine for a 750 with a healthy charging system by my recollection.

[scottly]

Yeah, that headlight shouldn't be too much load. You may want to inspect/clean the stator and field wire bullet connectors under the sprocket cover while you're waiting for the fuse box.

[evinrude7]

thanks calj and scott.  yep i'll do that.  payment went out to mark today for the panel.