reg/rectifer ?

[texaskaw]

1994 bayou 400. regulator/rectifier got real hot to the touch melted one wire connection in plug.replaced stator and reg/rectifier runs fine but reg/rect is still hot and yellow wires from alternator are hot.any ideas what might be.

[CRAZYKIWI]

They do run pretty hot. Make sure your battery is OK? Put a test meter across the battery terminals and check the charge rate is not over 14.5volts. Cheers

[texaskaw]

They do run pretty hot. Make sure your battery is OK? Put a test meter across the battery terminals and check the charge rate is not over 14.5volts. Cheers

multimeter shows 12.7 - 12.9 volts. it will drop to 6-8 volts for a second sometimes.

[oxidized_black]

is that when engine is running?

[CRAZYKIWI]

Might pay to have battery load tested at local garage or bike shop??

[texaskaw]

is that when engine is running?

yep,engine running

[CRAZYKIWI]

Sounds OK, but it would be good to have battery load tested to make sure and then you are good to go.

The Reg/rectifier does get hot, that is how it cools itself. Just make sure you keep the fins clear of dirt etc so it can cool effectively and trouble free. Cheers.

[texaskaw]

well put on a new battery Saturday.been starting fine until today ..battery down enough it wont crank .there is no spark at all when you put cables on like there may be a short or something......

now everthing on this piece of !@#$ has been replaced except cdi unit......I have checked all wiring many times...cant find short................................

[CRAZYKIWI]

OUCH! Can U unplug yellow wires to stator and check with ohmeter? Is there power to earth down through stator??

Cheers.

[texaskaw]

OUCH! Can U unplug yellow wires to stator and check with ohmeter? Is there power to earth down through stator??

how do I check voltage out of alternator/3 yellow wires from alternator.should be around 60 volts?multimeter from yellow wires to ground? all 3 wires?

[CRAZYKIWI]

OUCH! Can U unplug yellow wires to stator and check with ohmeter? Is there power to earth down through stator??

how do I check voltage out of alternator/3 yellow wires from alternator.should be around 60 volts?multimeter from yellow wires to ground? all 3 wires?

Unplug wires from alternator and start engine. test voltage out of each yellow wire-to ground- 60 volts minimum. yes.

turn engine off and check each yellow wire to ground with ohm meter. Should be no continuity to ground. no reading in ohms??

[texaskaw]

Unplug wires from alternator and start engine. test voltage out of each yellow wire-to ground- 60 volts minimum. yes.

turn engine off and check each yellow wire to ground with ohm meter. Should be no continuity to ground. no reading in ohms??

not grounded..but only 1-2 volts coming from alternator.I have been asking about the wires and regulaor getting real hot on 3 or 4 forums ,all said normal.the regulator plug was melted when I replaced it.pulled plug today from alternator its melted too.

I guess the stator I bought is bad.man I cant get a break on this money pit bike.

[CRAZYKIWI]

Sounds like alternator, sorry about your bad luck!

We get ours rewound here. Not sure who you could get to fix yours??

Cheers

[texaskaw]

bought a new multimeter...stator not grounded,alternator putting out 9 - 10 volts at idle,39-42 at higher rpm...

[marioweldinginc]

Im not familiar with this bike but anything above 14.5v on a 12v system usually means a bad alternator if the regulator checks out good

[CRAZYKIWI]

sounds better. The hot melted plug still worries me though that it may have a short to ground somewhere??

Does the new multimeter read higher voltage at the battery now??

[texaskaw]

sounds better. The hot melted plug still worries me though that it may have a short to ground somewhere??

Does the new multimeter read higher voltage at the battery now??

ill check battery tomorrow. I am going to check all wiring again this weekend.

[CRAZYKIWI]

Cheers.