Electrical Issues

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Safo
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Electrical Issues

Postby Safo » Thu Oct 24, 2013 9:33 pm

Ok, When i bought my 1990 fzr1000,Was sitting for almost 10 years, in a garage, It had 2 main electrical issues. it had an overcharging issue. I was able to fix that.

The plug from the Reg/rec was melted and had a hole in the side, one of the terminals was black. The termials didnt appear to be touching though. I have since replaced them both on both ends after swapping the rec. They dont get hot during operation.

The Ignition switch connection with the Red, Brown, And Blue wires was also melted. I cut some of the wire back and installed new termials on the red and brown wire. The blue wire and terminal seem fine.
Igniton switch is free of corrosion btw.


Okay now to my issue.
The Smaller ground wire get's warm at the connection plug along with the wires.
The red and brown wires seem to get hot when i have the headlights hooked up. I've let the bike idle to the point of the fan comming on, the wires seem to get pretty hot. This issue is much more noticable with the headlights hooked up.
This heating is most noticable with the headlights on.

What i've done-

Put di-electric grease on every connection i can.
Checked ground on engine, it was clean.
Taken wire harness apart and searched for broken, torn wires, not finding any. All the factory splices seem ok meaning not corroded.
Can't seem to find any shorts, in testing the red and brown wires on the ign circuit.

Tested the Headlight harness and everything seems to be ok too.

Can anyone tell me where and what else to look for as I am at my limits.
Could it be the connectors i used? I used a "heavy duty" type connector on the ignition wires. If not what should i run?
Would it possible i didnt trim the burned wire back far enough?
Could a relay be the problem?
:tks:

Safo
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Re: Electrical Issues

Postby Safo » Thu Oct 24, 2013 11:33 pm

FWIW, i noticed the Headlights seems to be getting a little bit hot just now. Not warm, but hot. The bulbs are the standard H4 60/55W. no corrosion. I think i'm may be on to something here... Going to try to check the relays....

DonTZ125
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Re: Electrical Issues

Postby DonTZ125 » Fri Oct 25, 2013 9:24 am

Safo wrote:The bulbs are the standard H4 60/55W. no corrosion.

To quote Jamie from the Mythbusters, "Well, THERE'S your problem." The bulbs for the dual headlight model were 2x 35/35W; the single headlight version had 1x 60/55W. You're cranking almost double the juice through your wires! :yikes:

Safo
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Re: Electrical Issues

Postby Safo » Fri Oct 25, 2013 2:35 pm

DonTZ125 wrote:
Safo wrote:The bulbs are the standard H4 60/55W. no corrosion.

To quote Jamie from the Mythbusters, "Well, THERE'S your problem." The bulbs for the dual headlight model were 2x 35/35W; the single headlight version had 1x 60/55W. You're cranking almost double the juice through your wires! :yikes:



:duh: :duh: :duh: Alrighty then then. DOH!!!!! :duh: :duh: We'll get some new bulbs today and see what happens.

Wouldn't the leads to the headlight bulbs get hot also if that was the case?

Safo
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Re: Electrical Issues

Postby Safo » Sat Oct 26, 2013 1:49 am

uPDATE: I was unable to find any h3 35/35 locally so I had to order them. Which seems liek a chore if i need them in a pinch. Any light upgrade threads to something more common on this forum ?

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Genesis
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Re: Electrical Issues

Postby Genesis » Sun Oct 27, 2013 2:59 pm

Safo wrote:Any light upgrade threads to something more common on this forum ?

I have heard of people running a new heavier replacement harness all the way back to the source, maybe DonTZ125 could help you out.....

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DonTZ125
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Re: Electrical Issues

Postby DonTZ125 » Sun Oct 27, 2013 3:06 pm

Using relays direct to the battery is a common upgrade for problems caused by 20yo wiring, but I don't think that was his question, and is something that can wait until we see what the proper using bulbs achieves.

Safo
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Re: Electrical Issues

Postby Safo » Wed Oct 30, 2013 2:06 am

Still waiting on my lights from boatsplus or whatever it's called :swear . They might ship them tomorrow, maybe have them by next week :swear :swear . My charging problem seems to have come back. After riding the bike today with no headlights, the battery voltage is at 13.9, charging voltage doesnt go above 14.7 though. I guess im buying a rectifier soon. Want to check it with the bulbs in though...

Safo
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Re: Electrical Issues:update

Postby Safo » Sat Nov 02, 2013 11:55 pm

Alright. recieved my headlights. System seems to be charging some what high still. As far as I can tell the wires are not heating up like they were before. I'm ordering a new VR on Monday. It also seems that I need to order some o-rings for the cooling system too. Allong with chain,sprockets and clutch. :duh: :duh:


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