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Thread: charging issue info! 04 onwards....

  1. #1
    fusebox
    Guest

    charging issue info! 04 onwards....

    just a quicky guys

    ive just done a job on my mate coventry nigels bike and found another brown block connector thats worth checking out before we right off stators!!

    The brown block connector we all love to hated and bypass is located on the right hand side of the bike under the fairing right by the REG/REC unit well there is a second.......

    the 2nd block connector is located between the V and had rubbed on the engine casing of nigels bike and had shorted on the block!

    Easy fix and most importantly .....cheap!!

    Hope this helps

    Griff

  2. #2
    Platinum Subscriber
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    Nice one Griff; most helpful as always.........thanks for taking the time; cheers !

  3. #3
    Badger
    Guest
    Quote Originally Posted by fusebox View Post
    just a quicky guys

    ive just done a job on my mate coventry nigels bike and found another brown block connector thats worth checking out before we right off stators!!

    The brown block connector we all love to hated and bypass is located on the right hand side of the bike under the fairing right by the REG/REC unit well there is a second.......

    the 2nd block connector is located between the V and had rubbed on the engine casing of nigels bike and had shorted on the block!

    Easy fix and most importantly .....cheap!!

    Hope this helps

    Griff
    Griff me old mucker, that one behind the coolant bottle is the one that most folk have bother with and hardwire, strangely on my 04 bike it has both of them, but my 06 bike has only the one at the regulator, first thing i did was cut it off and hardwire it so i dont have any brown connectors to cause problems.


  4. #4
    fusebox
    Guest
    ok it seems like the thick plottens!

    looks like they may have changed the wiring loom for the stator when they changed supplier or sommink!

    defo worth noting mate!!

    catchya soon dude!!
    Griff

  5. #5
    Badger
    Guest
    Unless Luigi has been on the forums and noticed the problem with the one behind the coolant bottle and thought maybe we should do something about it, so he went and drank two bottles of Pino Grigio and mistakenly went down to the paint shop instead of the factory floor, being pissed he thought he would have a laugh and painted a load of factory frames in gold

  6. #6
    spoonz
    Guest
    Quote Originally Posted by Badger View Post
    Unless Luigi has been on the forums and noticed the problem with the one behind the coolant bottle and thought maybe we should do something about it, so he went and drank two bottles of Pino Grigio and mistakenly went down to the paint shop instead of the factory floor, being pissed he thought he would have a laugh and painted a load of factory frames in gold
    It was a manufacturing update in 06 when they cut out the connector between the cylinders. It couldn't take the heat generated by the stator in high load conditions ie. if there was any resitance in the connector from corrosion etc.

    The stators otherwise remained the same and used the same manufacturer until later when a 380w version became available (original is 500w). That was after Honda and Denso made it known that the 500w version ran too hot.

    Honda offer an extended 2 year warranty on the 500w version due to it's problems.
    Aprilia offered errr nothing but made both versions available as a spare part.

    In short the post 04 flywheel has a much higher magnetic field and the stator has more wire on it's windings. Problem was the wire is bordering on too thin guage for the 500w output but they couldn't then increase it's thickness because it then wouldn't fit in the flywheel.

    Solution - reduce the winding amount to allow thicker guage wire but that reduces it's output as there is less total wire on the stator. Hence back to 380w

  7. #7
    One Liter Duc Eater heroblob's Avatar
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    Spoonz you just never stop amazing me with your knowledge. how do you know all this stuff.

  8. #8
    spoonz
    Guest
    Quote Originally Posted by heroblob View Post
    Spoonz you just never stop amazing me with your knowledge. how do you know all this stuff.
    I don't get out much

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