Well after my battery went flat for the 3rd time this year (very random and intermitent problem) sometimes fine and once in a blue moon she'll run flat.
Anyway, after hunting for the problem today i found this (pictured below) was burnt out at the two larger connections and at the fuse....... BUT the fuse wasn't blown, just the plastic around it had melted and the REG was warm to touch.
Now i can understand that the REG will get hot if something is suspect with the charging circuit (due to the pic below i hope) BUT my question is what would cause that point to melt....... OVER charging, Genny problem?
If so where is the Genny located on these bikes (i assume under the left side engine cover??)
Voltage when tested at the battery and before this burnt point remained at 12V regardless of revs, Genny problem i guess???

Karl :)

I should also add that the battery was fully charged this morning, would the battery being fully charged cause the REG to heat up a little, burning off the excess current that the battery can't take?

Wow. That is the main fuse isn't it? Wires usually melt when there is too much current going through it, but I don't know why the fuse didn't pop.

vfrman wrote:Wow. That is the main fuse isn't it? Wires usually melt when there is too much current going through it, but I don't know why the fuse didn't pop.

Yeah i'm a bit baffled as to why the fuse didn't pop, as the fuse looks like it's directly connected to the two outter (larger) cables, which are the cables that have melted their plugs
I'm going to take her to a shop as I have limited tools here in Thailand and if i bugger the gasket when opening the genny cover i'm buggered because i don't know the Thai words for "have you got and oil resistant gasket glue thingy stuff" lol :D

Good luck!

Thanks for the luck, other than the Genny producing too much current (which it currently isn't).... no pun intended.
Could the Reg cause this to happen or other things?

Ideas are much appreciated :)

Yes. The regulator/rectifier does two things. First, it regulates the voltage from the generator down to the proper voltage. Second, it changes the voltage from AC to DC. If the reg/rec checks out and doesn't regulate the voltage properly, things begin to melt and batteries become fried. This is a good place to start looking. Check the connector to the reg/rec and see if it is melted. The unit is located on the seat subframe on the left side of the bike (if you are sitting on it).

karl BKK wrote: I'm going to take her to a shop as I have limited tools here in Thailand and if i bugger the gasket when opening the genny cover i'm buggered because i don't know the Thai words for "have you got and oil resistant gasket glue thingy stuff" lol :D

High temperature silicone sealant will do the job.

I've used it on customer's bikes in the past when a gasket was out of stock or unavailable for some reason. Never had a failure of the seal yet.

Sorry to bump this thread.

1) Now the bike fails to even get an ignition light and no sign of the starter moving at all on a new battery........

2) The medium size cables at the front of the picture above have power (red and red/white), yet the two behind (smallest cables) have no power at all, even with the starter button depressed........??

3) The starter button, has a permanent live on BOTH cables (in and out), is that correct?

4) The Kill switch works fine and has power when it should and cuts when it's in it's off position

5) If the Regulator is completely dead would the bike fail to show any signs of life??


In the picture above can i connect all four smaller wires to the main cable just to get the bike to a shop (living in Thailand)

Wow! You have had something major go wrong in there somewhere. Don't even attempt to do a temporary fix, you could make the situation worse. My advice would be to get it trailered to a bike shop if you are not sure how to fix it yourself.