Topic: Charging system nightmare.please help. well not really a nightmare but not fun

[timeguy87]

75 CB550 I have replace the rectifer and regulator with an updated all in one. The stator was burned so replaced that and the rotor because it looked to also be melted in the center from something. It will charge great testing it in the shop up to around 14 v but get out on the road and the brand new battery will last about 20-30 minutes causing the bike to quit subsequentially me to having to push the bike. 

[TwoTired]

what other electrical changes have been made to the bike?  Bulbs, coils?

[timeguy87]

the only thing else i have changed is a new flasher relay but this was happening before and after the relay.

[Alan F.]

Sounds like there's a short somewhere or a high resistance somewhere it shouldn't be, have you checked your wiring harness with an ohm-meter?  there's the possibility that a switch contact or fuse contact (or a corroded connector somewhere) could be oxidized causing a high resistance condition.
Have you checked with the manufacturer of the new all-in-one reg/rect for clues?
-Alan

[TwoTired]

the only thing else i have changed is a new flasher relay but this was happening before and after the relay.

I didn't ask what >you< changed.  I asked what has been changed from stock configuration of the bike.

It is hard to imagine a failure that would burn the stator and not effect the bike's wire harness.  The stator wires are far more robust.  How were the main harness and grounding wires corrected?

[timeguy87]

It is all stock unmolested no splices that i have found. Had to work late i am going to work on the bike tomorrow night.

[Toxic]

so did you get it resolved?

just curious as I am trying to learn as much about these systems before I tackle my own issues