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Mechanical and Technical Mechanical and technical topics, help, and discussions

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  • 1 Post By curve addict
  • 1 Post By FeralRdr
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May 5th 2018, 03:27 PM   #1
 curve addict's Avatar
 
  Apr 2016
  Des Moines, WA

  ...1987 Yamaha FZR1000...
Charging issue: sometimes ya just gotta keep looking

First off, sorry, no pictures.

My old 1987 Yamaha FZR1000T, with 31,000 miles, stopped charging this morning. As the alternator is a self-contained unit, I decided to look for and price another.

Discontinued.

As some components, though expensive, are still available, I then went back to my old training and started diagnosing the components:
Wiring to/from alternator, good. Brushes, good with plenty of material remaining. I then removed the voltage regulator, installed the brush assembly and bypassed the regulator by clamping the brown-wire, armature, terminal to it's usual place on the brush assembly (+) and installing a jumper wire between the other brush's terminal (that usually connects to the regulator) and ground.

Started the bike and slowly brought up the revs: 16+VDC output from the rectifier. Shut the bike down immediately. The regulator had failed; all else OK.

The Yamaha voltage regulator listed for about $280. Ouch!

Having nothing to lose, I set about opening-up and inspecting the regulator as far as I could without destroying it. Found a cold solder connection that had started arcing and had finally corroded. Cleaned and re-soldered the connection, cleaned all other electrical connection points between the components and smeared a little dielectric grease on all of them, reinstalled the regulator, and started the bike. Charging and holding at 14.6VDC at 3000RPM and up!

Sometimes a little perseverance, and a little schooling, pay off.

Edit: here is a follow-up on that little job:Follow-up
.
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Edited by curve addict on May 20th 2018 at 04:43 PM
May 5th 2018, 04:30 PM   #2
 Rock Dodger's Avatar
 
  Feb 2016
  Washington

Great job figuring that out! Most of us wouldn't know where to start on an issue like that.
May 5th 2018, 05:30 PM   #3
 Sentinel's Avatar
 
  Jun 2016
  Poor Tortured

  2015 Kawasaki Concours 14 - The Origame Sea-Dragon
i love it when people go old school and actually fix shit.

i fixed moms washer last week. the door switch had fallen apart. plastic crumbled. removed it and jumper-bypassed the circuit and told her to keep her hands out of it when it was spinning.

she said OK.

nice work, yo.
May 5th 2018, 06:12 PM   #4
 Scribbles's Avatar
 
  Jan 2016
  NW

I really like machines that are easy to take apart and fix. Too many newer contraptions require "buy a new unit..". I had a dishwasher with a failed pump (impeller was trashed), manufacturer told me that I had to buy a motor assembly to get that part as it wasn't offered by itself.
I bought a new dishwasher instead..
May 6th 2018, 08:22 AM   #5
 oldmanriver's Avatar
 
  Jan 2016
  Battle Ground

  1991 Honda CBR1000F
Can't help but think that it could have had something to do with a bad connector out in the boondocks. LOL
May 6th 2018, 08:59 AM   #6
 FeralRdr's Avatar
 
  Jan 2016
  Adjacent to the Hobbit Garage

Now we know who to call when the WiFi goes down.
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May 6th 2018, 12:03 PM   #7
 curve addict's Avatar
 
  Apr 2016
  Des Moines, WA

  ...1987 Yamaha FZR1000...
Thanks y'all. It feels good to pull-off an inexpensive, quality fix every now and then. Sometimes I miss my little service business, Doctor Wheelgood, but then I remember losing all of my summers and then scraping by during the winters. Been thinking of looking for part-time work in someone else's shop for a little extra cash.

Quote:
Originally Posted by oldmanriver
Can't help but think that it could have had something to do with a bad connector out in the boondocks. LOL
Possibly, but that solder joint was iffy from the factory. It finally gave out.

Quote:
Originally Posted by FeralRdr
Now we know who to call when the WiFi goes down.
Yes, someone else. For good or ill, I avoid tackling internet or computer-related issues. I'm a primitive soul, after all.
May 6th 2018, 01:24 PM   #8
 Motorbiker's Avatar
 
  Jan 2016
  Silverdale, WA

  1987 FZR 1000
I have pretty much bypasses the original multi connector on my FZR1000TC myself. A few years in the SoCal heat and it was melting the connector. I have a complete motor, 125,000 miles before I dropped in 1994 motor in my 1987 frame. I also have a complete front fork assy with Racetech gold valves. Needs seals. Good job on the fix.
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