I truly apologize for yet another electrical question. I have gone through more old posts than I can imagine to include Curly's diagnostics and I am absolutely stumped. So here's the situation...
78 XS650 complete cafe build
- Hand made minimized wiring harness.
- New Mikes XS combo regulator rectifier x 2 (both ohm test good).
- Rotor 5 ohms between rings - infinity to ground
- Stator tests good.
- New brushes
- Brown wire to keyed power source with battery voltage to brush
- Red wire to battery + with 20A fuse
- Black wire to battery -
- 3 white wires to stator wires
- Green wire to green wire
- Inner brush isolated with nylon screws.
Won't charge despite all being good. No magnetism at rotor with key on hooked up the way it's supposed to be.
Strong magnetism and will charge when regulator bypassed (green wire to ground), but voltage climbs > 16 volts with increased RPM as expected with regulator bypassed. (Step 3 of Curly's instructions).
Thought it may be R/R not being properly grounded because of where I mounted it (plastic rear inner fender splash/mud guard). Sanded down a mounting hole on the unit and ran ground wire from bolt/unit directly to battery ground, but still no joy.
Not sure where to go next. I went ahead and put metal screws back in the inner brush and it pops the main fuse (20A on red wire) when I turn the key on. No such thing with the nylons.
I can't get past step 3 on the diagnostics with either of the R/R units. Again no magnetism with key on unless jumped green wire to ground.
Again, sorry for the rehash and any help or thoughts would be greatly appreciated.
78 XS650 complete cafe build
- Hand made minimized wiring harness.
- New Mikes XS combo regulator rectifier x 2 (both ohm test good).
- Rotor 5 ohms between rings - infinity to ground
- Stator tests good.
- New brushes
- Brown wire to keyed power source with battery voltage to brush
- Red wire to battery + with 20A fuse
- Black wire to battery -
- 3 white wires to stator wires
- Green wire to green wire
- Inner brush isolated with nylon screws.
Won't charge despite all being good. No magnetism at rotor with key on hooked up the way it's supposed to be.
Strong magnetism and will charge when regulator bypassed (green wire to ground), but voltage climbs > 16 volts with increased RPM as expected with regulator bypassed. (Step 3 of Curly's instructions).
Thought it may be R/R not being properly grounded because of where I mounted it (plastic rear inner fender splash/mud guard). Sanded down a mounting hole on the unit and ran ground wire from bolt/unit directly to battery ground, but still no joy.
Not sure where to go next. I went ahead and put metal screws back in the inner brush and it pops the main fuse (20A on red wire) when I turn the key on. No such thing with the nylons.
I can't get past step 3 on the diagnostics with either of the R/R units. Again no magnetism with key on unless jumped green wire to ground.
Again, sorry for the rehash and any help or thoughts would be greatly appreciated.
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