SH775 frustration

[Guest]

I posted a few weeks back about what I assumed to be a faulty SH775, as unlikely as this could be. I verified stator output (new stator) both at the stator wires themselves and at the SH775 connector that I fabricated. I grounded the SH775 negative connection directly to the battery and the mounting bolt directly to the frame. I even tried grounding the mounting bolt to the battery. All of this led to zero volts output on the positive connection of the SH775. I took readings from the connector on the wire and directly from the SH775 spade itself. So I assumed the SH775 was faulty.

I ordered another SH775 (this one is an AA, other was AB) and experience almost the same results. This time I would get either 0 volts or it would read a little bit negative, which I found to be odd. I don't believe the chances of me having two bad SH775's are very high so I must be doing something wrong. It's not rocket science and I successfully installed one on my old 650. Stator wires connect directly to the grey side of the SH775. Positive goes on the left side of the black connector, middle is open and ground goes on the right side of the black connector, and is connected directly to battery negative. SH775 body is grounded to the frame of the bike. ZERO volts output from the SH775 positive no matter what I do.

What am I doing wrong?

Frustrated in Essex.

[roeme]

Okay, so let's try my hand at this....let's collect all the bits first...

1. Stator good ? Assuming Yes, but for completeness sake; what are the resistance measurements (betweens windings and to ground, for each)?
2. Stator/Rotor no. of poles match?
3. Generator AC no-load voltage?
4. Generator AC voltage under load?
5. Wiring in good nick? (Assuming yes, since new)
6. If all of these are OK, I'd put the SH775 on a bench and test it under lab conditions. Hard to imagine that you've got two duds, but this way you'd know for sure.

Since you've got two, you can already start with 6. If you don't have the means, maybe there's a GSR member properly equipped nearby. I'd do it (I'd give me an excuse/motivation
to finally get/build a three-phase bench supply) for postage, but unfortunately I'm across the big pond, so sending a package might be cost-prohibitive anyway...

[cowboyup3371]

what your multimeter set on - DC or AC volts? Are you sure it is working properly? Where are you testing the connection at - the battery or the R/R itself?

[bccap]

If I recall your other thread correctly. Your old R/R works when hooked up and your new ones don't. Try posting up some pictures of how you hook the two of them up and someone may have an answer for you......

[Nessism]

Just to be clear on the connections...



Grounding the SH775 body to the frame is unnecessary since the unit does not ground this way.

[Guest]

Just to be clear on the connections...



Grounding the SH775 body to the frame is unnecessary since the unit does not ground this way.

Exactly how I installed it. My negative line was connected directly to the battery. My positive line is where I was taking my voltage readings when the bike was running. To be clear, the positive line is not connected to the battery at this point. I'm just taking readings with my multimeter by connecting the positive lead to the positive R/R output and grounding the multimeter negative lead.

[Guest]

Okay, so let's try my hand at this....let's collect all the bits first...

1. Stator good ? Assuming Yes, but for completeness sake; what are the resistance measurements (betweens windings and to ground, for each)?
2. Stator/Rotor no. of poles match?
3. Generator AC no-load voltage?
4. Generator AC voltage under load?
5. Wiring in good nick? (Assuming yes, since new)
6. If all of these are OK, I'd put the SH775 on a bench and test it under lab conditions. Hard to imagine that you've got two duds, but this way you'd know for sure.

Since you've got two, you can already start with 6. If you don't have the means, maybe there's a GSR member properly equipped nearby. I'd do it (I'd give me an excuse/motivation
to finally get/build a three-phase bench supply) for postage, but unfortunately I'm across the big pond, so sending a package might be cost-prohibitive anyway...

1. Stator is good - brand new from RM Stator. Works fine with the stock R/R. I honestly can't recall the resistance measurements, but when I installed the stator I did these checks and everything was good. Like I said, the stator works fine with my stock R/R
2. Yes, poles match.
3 & 4. When the bike is idling I'm getting 27-28 volts AC across two poles. Consistent for all 3. I didn't check under load.
5. Wiring is brand new with new connectors, installed with a compression crimper.

[GSXR7ED]

I have this new R/R and have yet to install it. I'm told it's not too intense to install. I'll be viewing this thread for pointers.


Ed

[Guest]

what your multimeter set on - DC or AC volts? Are you sure it is working properly? Where are you testing the connection at - the battery or the R/R itself?

DC volts for measuring R/R output, AC for measuring stator output. It's working properly - tested against by battery and the stock R/R.

When I'm checking the voltage output from the stator I connect the positive lead of my multimeter to the positive lead of the R/R. I ground the multimeter to the frame or battery. The R/R positive it not yet connected to the battery. I wanted to confirm output before doing so.

[Guest]

I have this new R/R and have yet to install it. I'm told it's not too intense to install. I'll be viewing this thread for pointers.


Ed

Hi Ed,

I installed on on my old GS650 and it was easy. Worked like a charm.

[Guest]

If I recall your other thread correctly. Your old R/R works when hooked up and your new ones don't. Try posting up some pictures of how you hook the two of them up and someone may have an answer for you......

That will have to wait. I got frustrated and connected to the old R/R again. It's a bit of a pain to get at everything in the Katana. Remove the seat, remove the seat mounting bracket, remove the side panels, remove the airbox. Then you can get at the battery and connections.

Yes, I'm whining. :-)

[Nessism]

Exactly how I installed it. My negative line was connected directly to the battery. My positive line is where I was taking my voltage readings when the bike was running. To be clear, the positive line is not connected to the battery at this point. I'm just taking readings with my multimeter by connecting the positive lead to the positive R/R output and grounding the multimeter negative lead.

Both + and - need to go to the battery. Then run the engine, rev up to 5000 rpm, and check DC voltage across the battery terminals. That's how you check charging voltage. Testing without the + connected doesn't place any load on the system.

[posplayr]

DC volts for measuring R/R output, AC for measuring stator output. It's working properly - tested against by battery and the stock R/R.

When I'm checking the voltage output from the stator I connect the positive lead of my multimeter to the positive lead of the R/R. I ground the multimeter to the frame or battery. The R/R positive it not yet connected to the battery. I wanted to confirm output before doing so.

R/R has to be connected to a battery to test. This sounds like the whole problem you are having (i.e. R/R (+) is No-Connect). Doing it this way the R/R(+) voltage is going to vary depending on how the R/R was designed. The SH775 is probably just disconnecting which is why you see zero volts.


How is it you say you followed the directions for connecting the SH-775 but you don't have an R/R(+) connection?

[Guest]

Damn. Thanks for pointing out the glaring error in my installation. I'll give it another shot tomorrow. I had already successfully installed a SH775 on the old 650 so didn't feel the need to re-read any instructions. Apparently I was wrong.

That said, the first SH775 was connected to the battery neg and the pos pigtail connection in the wiring harness, and was not charging, or at least it looks to be that way because I ended up with a dead battery after a ride. That said, considering my installation error that may not be the case. I'll test both and report back.

Thanks for catching this!

[Guest]

Happy to report that BOTH SH775's work just fine, now that I've installed properly and tested them. Just home from a 1 hour ride and the battery is fully charged. All is well. Thanks again for pointing out the error of my ways.