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Discussion Starter · #1 ·
So I had an issue with the original stator rectifier it was stock. The wires and melted the connection melted I replaced the wires the stator the rectifier and the battery due to the battery overcharging and then not holding a charge. After I replaced the stator and rectifier and the wiring harness accompanied to both it melted again and it's overcharging again. Is there a wire that I could have put in the wrong spot? Do they have to be connected in a specific order? Or is there something else I should be looking at?
 

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Possibly, the Brown wire is a system monitoring wire after the ignition switch. On the OE regulator/rectifier this wire tells the regulator to output more power if the system voltage drops.
 

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Discussion Starter · #3 ·
Possibly, the Brown wire is a system monitoring wire after the ignition switch. On the OE regulator/rectifier this wire tells the regulator to output more power if the system voltage drops.
So how do I go about saying if this wire is reading the proper voltage?
 

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Normally the only way this wire will drop voltage is if the ignition switch internal contact is dirty, or the plug wires are dirty, or battery and starter solenoids.
 

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Discussion Starter · #5 ·
I guess I'll have to wire it again. Make sure I removed all the bad wire. The thing is over charging. So you're saying that the voltage is reading low so it's putting more out. I don't think it's spark it runs strong. So the ignition switch might be an issue?
 

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There is a possibility that the headlight ON diode in the fuse box has gone short, and this will then feed AC into the DC system, this may be the cause.
 

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Are the stator and rectifier still avialable as stand-alone parts for your bike? I have the same problem with my 7. What was your volt reading at the battery when engine was at normal op temp? Mine was 15.2v.
 

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Discussion Starter · #8 ·
Yes they are sold separately. The small light from the headlight was smashed. I'm not sure how high the voltage is, I didn't test it at rev. Seems like a lot of possibilities. Where is the diode? Is it in the relay?
 
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