Black Betty

[giant_mtb]

Don't get rid of it. You'll regret it when you get the itch to go for a two wheel ride. 

[CaminoRacer]

http://www.zx14ninjaforum.com/messages.cfm?threadid=18D57080-1372-66AE-3B196DDB76162E0F

Other people with older bikes have had problems with voltage regulators allowing the battery to overcharge. I have a new style regulator from a Polaris sitting on the counter at home... Probably should have installed that a few months ago and saved myself a $200 towing bill.

[CaminoRacer]

Shorai sent me a new one for free.

[12,000 RPM]

Don't get rid of it. You'll regret it when you get the itch to go for a two wheel ride.

I haven't got an itch in nearly a year. Maybe longer if you take out the track day. I'll probably be back, but it will be in a couple of years.

[CaminoRacer]

Swapping an SH775 R/R onto the bike now. Just realized that my old rectifier wasn't even grounded... The black wire comes out and connects to the metal body of the rectifier, which is normally bolted to the metal airbox. But I removed the airbox and the rectifier has just been ziptied and hanging in the air...

Oops. It probably works just fine with a ground! But I'll replace it anyway - the series SH775 will work better and run cooler.

[CaminoRacer]

Bike runs now, but won't rev over 6k. Might just be a dirty carb. I'll dig into that another day.

[CaminoRacer]

Voltage is 13.7 with the bike off, 13.2 all the time with the bike turned on, no matter what rpm. Should be at least 13.5 above 2000 rpm. Up to like 14-14.4 at 5k rpm

Either the wiring connection to the new R/R is insufficient or the stator is wonko

[CaminoRacer]

Low beam burned out so we gonna try this bad boy.

[MrH]

Let me know how you like it.  Was considering trying something similar.  I didn't like the idea of a fan in the base of the bulb though.

[Gotta-Qik-C7]

Let me know how you like it.  Was considering trying something similar.  I didn't like the idea of a fan in the base of the bulb though.

I run LEDs in the headlights of my 'Rolla and the Fogs in the C6. The fans don't cause any issues......

[CaminoRacer]

I'm hopeful. Stock stator output only supports 35W bulbs, which are super dim. These are 32W and should be a lot brighter

[CaminoRacer]

It works! Quite well.

The dash lights didn't turn on, nor did the tail light (but the brake light works). Still doesn't like to rev. I'm guessing my battery melt down screwed up all of that as well as burning out the previous headlight bulb. I'll have to check all the wires and bulbs.

edit: after staring at the wiring diagram, I think the gray wire is the culprit for the dash/tail lights. It's the common link and doesn't connect anything else. Since the brake lights still work, I know the rear LEDs are still OK and not burned out, so it's gotta be a wire. The diagram doesn't appear to have them wired in series.

[CaminoRacer]

So my new regulator/rectifier wasn't getting AC voltage through all 3 wires with the burned out headlight bulb. One of the wires is linked to the headlight circuit, so it only gets 2/3 voltage with the light off and full voltage with it on. I replaced the bulb and now it's working normally, but I'm still not getting more than ~13.7 volts at 5k rpm and the bike doesn't want to rev much higher than that (probably because the coil isn't getting enough voltage to support that much spark).

I ordered a new regulator (again), because it's gotta be an issue with this used Polaris regulator. I went with the SH775 series regulator because it's supposed to run cooler and stuff, but they're expensive to buy new and apparently used ones are a crapshoot. The older shunt style ones can be had for $20.

[CaminoRacer]

The new regulator didn't do anything to help the problem. I'm currently trying to get the stator cover off. The stupid JIS-head screws are totally seized. I've extracted 2 out of the 7 so far. I ordered a JIS t-handle screwdriver to see if that can help get the other 5 off, otherwise I'll extract those are well. They'll all be replaced by stainless steel hex cap screws because screw these JIS screws.

[Eye of the Tiger]

The new regulator didn't do anything to help the problem. I'm currently trying to get the stator cover off. The stupid JIS-head screws are totally seized. I've extracted 2 out of the 7 so far. I ordered a JIS t-handle screwdriver to see if that can help get the other 5 off, otherwise I'll extract those are well. They'll all be replaced by stainless steel hex cap screws because screw these JIS screws.

Impact driver?

[CaminoRacer]

Impact strips the heads too. The metal is too soft and Philips style screws are the worst

[shp4man]

It's a special tool for bikes that turns the Phillips head screw when you hit it with a hammer.

https://www.amazon.com/ARES-Reversible-Applications-Disengage-Fasteners/dp/B077D298R7/ref=asc_df_B077D298R7/?tag=hyprod-20&linkCode=df0&hvadid=309763890402&hvpos=1o1&hvnetw=g&hvrand=9765252463798410765&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=9031309&hvtargid=pla-569147419830&psc=1

[SVT_Power]

It's a special tool for bikes that turns the Phillips head screw when you hit it with a hammer.

https://www.amazon.com/ARES-Reversible-Applications-Disengage-Fasteners/dp/B077D298R7/ref=asc_df_B077D298R7/?tag=hyprod-20&linkCode=df0&hvadid=309763890402&hvpos=1o1&hvnetw=g&hvrand=9765252463798410765&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=9031309&hvtargid=pla-569147419830&psc=1

When did impact screwdrivers become a special bike tool? 

[CaminoRacer]

One of those didn't work either. Nor did an actual JIS screwdriver bit. So I'm gonna have to drill/extract all of them.

Philips style heads do not belong on vehicles unless it's screwing into plastic.

[MX793]

Impact strips the heads too. The metal is too soft and Philips style screws are the worst

Slotted screws are the worst.  Philips are second worst.

[Eye of the Tiger]

When did impact screwdrivers become a special bike tool? 

It's not just for bikes. It's for trikes, too. Oh, and anything with screws and bolts.

[CaminoRacer]

Slotted screws are the worst.  Philips are second worst.

True. But most people are smart enough to not use a slotted screw on anything that is very tight.

[CaminoRacer]

My extractor bit broke off 

[93JC]

Sheeeeeeeeeeeeeit. I didn't even know "JIS screws" were a 'thing'.

[FoMoJo]

True. But most people are smart enough to not use a slotted screw on anything that is very tight.

You shoulda got a Harley .

[CaminoRacer]

You shoulda got a Harley .

I'm just trying to get this cover off so I can check the stator. And once I get this electrical thing figured out, there's a good chance I'm gonna sell it!

[CaminoRacer]

I used a center punch and a hammer to try to get the broken bit out of the head, and it actually managed to loosen the screw instead of getting the broken bit out. I won't complain.

4 more to go.

[CaminoRacer]

OK so I got all the bolts out. Stator looks fine. Could it still be bad? I'm wondering what else it could be. Ignition coil?

[Gotta-Qik-C7]

OK so I got all the bolts out. Stator looks fine. Could it still be bad? I'm wondering what else it could be. Ignition coil?

Yeah that looks fine! Do you have a retifier?

[CaminoRacer]

Ok so I have a couple of lights that aren't working right now either. The tail light doesn't come on with the headlights, even though the brake light works fine (same bulb). Neither do the dash lights for the tach or speedo (but all of the other dash lights work fine). In Park, neither the tail light or the front yellow bulb in the headlight comes on. The two affected wires are the gray or brown wire on the wiring diagram. They go through the ignition switch and lighting switch. The lighting switch is where the gray wire originates, and it also happens to be where one of the stator wires goes through (so the stator is only running 2/3 power unless the headlight is on?)

If I replace the lighting switch, it might solve all of these issues. I'll do some testing tomorrow.