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Posts posted by Nelso90

  1. Hey guys, guess 40k miles is time for me to get on the electrical gremlin bandwagon here with my 2002 non ABS.

    The issues began about a month ago, at work. Key on, hit starter, and she was dead. I tried to jump start the bike, but the second I removed the auxiliary battery, it died. Went to Interstate (In a 52hp Diesel Jetta) to get another battery, installed it, ran great. I figured the battery was sulfated and it had an internal short.

    Fast forward another month and it did the exact same thing. I knew about the R/R and stator issues, so I figured I would tear her down and see what was up. Lo and behold...whoa


    So the R/R to stator connection was bad. I assume this means the R/R is bad also. I ohmed the stator out per sec. 17 of the shop manual, and everything was within spec. All I have read on the R/R is that I cannot test it at home. I figure it's bad though since the connector was fried.


    Really fried.

    I checked voltage through the battery negative as I did in the first place to determine if there was still a current drain and there was, I calculated it to approximately 0.4 amps, more than enough to kill a battery in a night. This being the case I made my way through the wiring diagram, looking over all the fuses, and I ran across a couple of items. The first was the red connector over the green starter relay. It was melted on the terminal that takes the RED wire. I pulled the fuse (30 amp, main fuse A), which caused the current draw from the battery to stop. I also noticed the holder for main fuse A was slightly discolored, but I do not view it as a contributing issue yet. Disconnecting that fuse did nothing to my current draw.

    Once I isolated the current draw to that circuit, I followed the red wire to the keyswitch, which tested good per sec. 20-21 of the manual. I then followed the red/green wire to the instrument panel and unplugged that 20 pin connector, which stopped the current draw.

    To summarize,

    This bike keeps killing batteries

    I found a totally destroyed R/R to stator connection

    Stator ohmed out OK

    Battery still is being drained whilst R/R is NOT connected (0.43A @ 12.7V battery voltage)

    30 amp Fuse A connector is melted at green connector (red wire)

    30 amp Fuse B connector is beginning to discolor.

    Current draw ceases once Fuse A is pulled

    Current draw ceases if instrument panel (20 pin) plug is disconnected (no discoloration on this connector)

    I am pretty stumped as to why this is happening as it seems nobody mentions instrument panel, nor the fuse on the starter solenoid. Any suggestions on what I should test/replace? I figure I am in it for a new Rectifier and fuse holder, but I fear it could be more.

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