what csuses a motorcycle voltage regulator to get hot
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posted July thirty, 2008 12:56 AM voltage regulator and wires getting very hot...
I am trying to become my wheel ready for the DYNO and while I had it running today I noticed south slight fleck of smoke coming from the wires that attach to the regualtor that some fromt he stator. In the pic you will see me pointing to where the smoke was coming from. Only that side of the wires seem to eastward hot. I replaced the regualtor its self as I had a spare but that did not seem to exist much help. The regualtor gets so hot you cant hold your paw on it.
Whatever ideas why? Bad stator?
I checked all the wires between the stator and the reguator and nothing is pinched.
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posted July 30, 2008 02:21 AM
Edited By: ridgeracer on xxx Jul 2008 09:28 Did you pull the connector apart and bank check the pins? This is a known problem with these bikes. There is actually a call back notice or service bulletin floating around out at that place nearly it. If I remember correctly the positive crankcase pressure in the generator cover over fourth dimension forces oil up the white wires and it gets into the contacts in the plug which increases their resistance which makes them get hot. They eventually burn out the plug.
You should get it checked out it has been known to start some bikes on burn.
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posted July xxx, 2008 02:24 AM 
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posted July xxx, 2008 02:29 AM We'll Karl had told me to try that and I did cutting that connector out merely it did non help my problem.
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DJ JONES
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posted July 30, 2008 03:28 AM Thie isn't cycle specific but mayhap it will assistance diagnos the prob.
http://www.electrosport.com/
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posted July 30, 2008 04:04 AM #
dj_jones
is in that location some oil inside the plugs ??
woppi
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posted July 30, 2008 04:20 AM Yes there was. I removed the connecter and difficult wires the wires merely the problem still exists.
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posted July 30, 2008 07:43 AM Regulator/rectifiers do get hot, that's the reason for the large heat sink. At present that you've difficult wired it the wires should be cooler. Maybe someone with a temperature gun could measure out theirs and you could do the same to see if yous're back in the brawl park.
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posted July 30, 2008 09:39 AM Understood but this seems excessive to me....
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posted July 30, 2008 12:16 PM did yous get a higher output stator(rewound) for your electronics? that would heat it up more, plus the oily wires increase resistance....hmmmm
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posted July 31, 2008 12:04 AM quote:
...the oily wires increase resistance....hmmmm
The oil gets betwixt the contacting surfaces of the male and female plug pins. The increased resistance is at the pins and that is why they get hot.
Watts = Amps 10 Amps x Ohms
If the plug is conducting ten amps and the contact resistance goes up merely 1 ohm that is 100 Watts. Imagine the estrus given off by a 100 Westward light bulb full-bodied in that trivial plug.
Speaking of watts calculations information technology applies to the finned box which is in fact a rectifier / regulator. That thing on the left side of the engine is in fact an alternator and generates alternating current. That ways the direction of current in the wires from the stator is constantly alternating.
The rectifier converts this Alternating Current (Air-conditioning) to Straight Electric current (DC). DC current only flows in ane direction, like a bombardment. Each of the diodes ( a kind of electron check valve ) in the rectifier drops the voltage nigh 0.6V. At 10 amps RMS that is 6 watts per diode or virtually 18W.
The regulator, as the proper noun implies, tries to keep the voltage at a steady level but information technology can only go along the voltage from going above a certain voltage. Information technology does this past interim similar a automatically varying resistance betwixt the source (alternator via rectifier) and the load (bicycle electronics). Again anytime we have resistance we have heat in watts.
If the voltage coming into the regulator is 20V and the voltage coming out is 14V that is a drop of 6V. If the current is ten amps so A x V = W; 6 ten 10 = sixty watts. Plus the 18 from the rectifier makes 78 Watts. The thing is going to get warm. As someone else said that is why information technology has cooling fins.
At present these are just back of the napkin figures, your mileage may vary equally they say. But the math is pretty elementary here and tells u.s. something we all know intuitively. Increase the load (amps) increase the oestrus.
If in fact the regulator is running hotter than normal only i of three things can exist happening.
1)The bike circuits are drawing more a normal load
2)The alternator voltage is higher than normal
iii)The frigging thing is broken.
You say you swapped it out and then its not likely number 3. If the stator is stock its unlikely to be number two.
Take you added any electric accessories to the bike lately?
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posted July 31, 2008 02:23 AM No new electronics.
Guess it is fourth dimension to try my spare stator....
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posted July 31, 2008 03:24 AM DJ,
see what voltage is getting to the bombardment.
if voltage is right, i wouldn't do anything,
warm wires? maybe they should be warm (picking up heat from the rectifier)
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posted July 31, 2008 03:26 AM The regulator is and so hot you lot can non put your manus on it. Is that correct?
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DJ JONES
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posted July 31, 2008 04:44 PM hey dj_jones i just had the same problem tonite, started smoking on me, so what did u end up doing???? did u just cut that plug out and hard wire it??
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posted July 31, 2008 x:23 PM If your bike is stock and you havnet done anything take it to the dealer as they have a recall and volition fix it all upwards.
I have temporaily disconnected my stator only I do not run my bike on the streets.
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DJ JONES
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posted July 31, 2008 10:36 PM I'll attempt sending the link to this site again. They have a PDF troubleshooting guide which can be downloaded. It's very helpfull.
http://www.electrosport.com/technical-resources/library/diagnosis/mistake-finding-guide.php
Skillful luck,
Rick
Source: http://bikeland.org/board/viewthread.php?FID=1&TID=40877
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