Fixing a Faulty Charging System

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In this video we test out a common failure point when it comes to old vintage motorcycles. On this KZ400 we find that it has a faulty rectifier unit and we get to knock out two birds with one stone buy using a product from Rick's motorsport electrics to replace the unit with a more modern sealed charging system component.
Join in and discover how easy it can be to test ouut a faulty part when it comes to your charging system.
ENJOY!
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[@David-op5fs]

I am old man mechanic. I have been repairing and restoring these old bikes for 43 yrs. I have watched ALOT of videos. Out of them all, UR THE MAN.

[@TheMotorcycleMD]

That means a lot David, thanks man!

[@jeffrygagnon5506]

@@TheMotorcycleMD Hey Doc-- You deserve it! "It don't come easy. And you know it don't come easy." (Richard Starkey)

[@biggooddad]

As an an old Electronics Tech, i admire how you break it down to understandable layman's terms that are hard to find these days. 👍

[@TheMotorcycleMD]

That is how I learn myself! 👌🏻 Thanks for the compliment.

[@jeffrygagnon5506]

Gotta say it too, Doctor: Nice job. Really. I usually get way ahead of myself on electrical probs - often to no end. This vid got my approach back on track. Thanks. My no. 1 love is a '91 Honda Nighthawk 750 ("Tokyo Rose") which I bought w/19k mi., after 23 yrs of unused storage. (You seem to also love these ol' girls). Rigged her immediately for touring (National Cycle windshield-fairing, and WAY expanded luggage capacity for the backrest, pillion, and factory luggage rack. She's now @ 88k mi. of interstate flight (gotta love it), without the head ever been removed.. Valve cover gasket has been Rose's biggest (and only) "permanent" repair/replacement. Just now starting to burn a bit of oil @ constant hi-speed running. God bless her. And charging system like new again, thanks to Dr. Cody. Take a bow.

[@jeffrygagnon5506]

Yup. Vids keep on gettin' better, don't they? Seein' something done is worth a thousand words.

[@TheMotorcycleMD]

@@jeffrygagnon5506 glad it could help man!

[@colinculverwell325]

Good video and easy for anyone to follow. I've just replace the whole chargingi/ ignition system on my ' 77 RD250 after it failed. Went for a Vape system. Expensive but you do get piece of mind as standard. Saves the long push home as well.

[@TheMotorcycleMD]

Peace of mind is everything man! Good fix 👍🏻

[@jeffrygagnon5506]

If you don't mind "expensive". But then, this activity IS expensive. Still a well-spent bit of whatever else you may have.

[@kimsmith4409]

Outstanding easily understood commentary thank you 👍👍👍

[@TheMotorcycleMD]

Thanks man!

[@kcbandit8925]

Great video. You made the fix very clear to a electronics dummy.

[@TheMotorcycleMD]

Thanks for the compliment brother 🤙🏻

[@The_M-An-M]

Great video as always

[@davros517]

Spot on explanation and brilliant diagnostic tutorial, thanks

[@RuSerious117]

Good stuff Cody, love the content and great editing…I don’t have a bike to work on, but I’ll add a comment to help the algorithm ;)

[@TheMotorcycleMD]

Means a lot man! Thanks for stopping by.

[@crnutsmotorsports]

Very educational.

[@johnboudreau6810]

I used Ricks for my bike's electric's. Worked great afterwards

[@TheMotorcycleMD]

Right on man!

[@cross13000]

Great video.

[@jordenc8417]

love you vids man, dont suppose you have a video on replacing a honda shadow 05 vt750 clutch starter or similar, about to undertake that job and its my first time delving into the engine bay, thank you for any help you can provide :)

[@swordfish1120]

Good vid. Question on using a lithium battery with a stock voltage rectifier for 88 Honda NT650. Will a stock rectifier heat up more when using a lithium battery? Have you seen charging problems using a lithium battery with a stock rectifier? I tested my rectifier with my multimeter and diodes were all consistent values running one way.

[@TheMotorcycleMD]

Good question. To date, I have not seen an issue with this set up. The rectifier is still a pre-battery component. Rectifier sends the voltage to the battery. Rectifier is still simply taking the AC from stator and changing it to DC. Doesn’t matter what battery is in there. What I do know is that lithiums get back to full charge much quicker. I still don’t think this affects the regulator. The best thing you could do is likely to put a digital read out attached to the battery. This way you know that it is not being over charged if the system starts to fail. Overcharging a lithium battery is bad lol

[@swordfish1120]

@@TheMotorcycleMD Thank you. Good tip on the digital readout.

[@alcapon-o3f]

Question , I have a 95 virago 750 the bike didnt want to start so finally got it started and it was not charging properly so I replace the regulator rectifier and a new battery solved that issue so , bike is still running slightly rough but blew the headlight bulb , so I did a voltage check again on the battery at idle 13.46 volts when you give it throttle 19 volts and climbing . So in your honest opinion what would be the next solution is it possible something is burning up the regulator or did I get a bad one from the market?

[@tboyko4802]

I have a 2007 kawasaki zzr600 parked it a few years ago sat out side for a few month, I went to put it back together at the beginning of this month it would crank but would not fire changed the fuel pump crank no fire but now it's gets power but does not crank or anything. I also have a Chinese atc that does the same

[@josecontreras1712]

Hey man so I have 1982 cb750 Honda and I already installed a new rectifier and a new stator and with a new battery but it doesn’t spike higher than 12 when revving what else can I change? I just started working on project bikes so your help would be appreciated!

[@prakashkrisanan8523]

Hi bro, nice to hear from u 😊.. I facing 1 issue bro with my motorbike KTM Duke 200 abs. I already changed new battery at my motorbike. After install the new battery I check the battery voltage is good using multimeter the voltage is 12.58v.then I turn on the key suddenly the battery voltage drop until 4.05v.i don't know what parts make my battery voltage drop bro. Please give some solution to I check and fix the issue bro. Thank you for your support bro.

[@swordfish1120]

Cody, let me know if you have a video that may help me deal with the following issue: 88 Honda NT650 I changed the stator because the voltage was not increasing to the battery when I tested voltage to the batt while rev bike to 5K and batt loss voltage while testing. After replacing the stator the batt was steady and voltage showed increase voltage when leads were on batt while bike rev to 5k. The bike was running for about 5 minutes and then died. I have hd light & running lights, but nothing happens (no crank or any sound) when I hit start button but hd light draws down like normal. Batt is a lithium and shows 13.45V. Also, I lost the neutral light. Any thoughts?

[@elmilusos208]

Brother, I hope you can answer me. I have a problem with a Yamaha Vstar 650. The exhaust pipe turns red hot right where it screws onto the cylinder What could it be? Thanks!

[@gabem.5691]

I'm not a motorcycle mechanic, but I have been told this is a symptom of it being too lean, not enough fuel. If it's at idle it can be the idle fuel screw or your have dirty carbs/ jets too small. I recommend posting on a forum related to vstars

[@josht.m9697]

i have a Suzuki intruder vs400cc and now it feels like a 50cc any hints to look at ?

[@jeffrygagnon5506]

Some questions first: What was the best it had ever run? When was it last serviced? If so, what was done?

[@josht.m9697]

@@jeffrygagnon5506 iv had it two 2 years never had it serviced, its had curbs cleaned . new air filters. spark plugs. new coolant fan .new oil ,, someone said it could need a service but will have to wait till after xmass to book it in ffs best it ever ran its been good till about 3 months ago then it started cutting out after about 70 miles but it would start right back up on first press off switch then go again and then it kept losing power and cut out but then it start on first press off switch

[@jeffrygagnon5506]

@@josht.m9697 Hi josh-- Appears that you REPLACED a lot of stuff not necessarily related to your problem. With the performance issue you have, sounds to me like an undiagnosed fault in your air intake system, including (but not necessarily) a mixture that may be way too rich. -- which would run OK cold until lack of h2o/oxygen smothers it warmed up. Pull a spark plug. If the business end is black and gummy, it's prob a lack of air to gas ratio. That could be faulty timing, or something as simple as incorrectly installed air filters. And please, josh, remember - I am just an intern. If anyone can diagnose such problems online, that would Dr. Cody, MD. And I now turn it over to the good doctor ;o) _Wanna get there? Get a Honda_

[@josht.m9697]

@@jeffrygagnon5506 thanks dude , il have a look at spark plug once it stops raining in wales uk 🤣🤣😎

[@jeffrygagnon5506]

Cody-- Why does it now say "@" before my name when I post, when it's actually a response?

[@TheMotorcycleMD]

I have no idea man.

[@benderbender1233]

😎🤙

[@benderbender1233]

wish u were l0cal cuz eye cud sure use sum help wiring up a cdi b0x 0n my 1985 kawasaki en450-a1 eye g0t given t0 me. c0nnect0r iz g0ne (entire harness actually) & wiring diagram sh0ws 1 r0w 0f 10 wire wen in reality da cdi b0x has 2 r0ws 0f 5 wires. 😖

[@jeffrygagnon5506]

@@benderbender1233 A real _chore_ to read your post. Did you intend that?

[@benderbender1233]

@@jeffrygagnon5506 😉👌

[@benderbender1233]

@@jeffrygagnon5506 u jus really g0tta want t0 kn0. reading it 0utl0ud helps im t0ld. ✌😁

[@jeffrygagnon5506]

@@benderbender1233 ?