Triumphrat

jscoggin · 04-25-2008

I have a 2002 Daytona Centennial Edition. I think I might have a bad regulator. I left the key on and the battery ran dead. I charged it and the bike was still dying, so I replaced it. The new one is in and the bike is still dying, leaving me to believe it's a bad regulator. I'm taking the new battery back for testing, but my question is. How to I test the regulator to tell if it's bad?

jscoggin · 04-25-2008

So, I didn't get a chance to test the new battery because the shop closed. But I called the local dealer and talked to him for a minute about the regulator. He mentioned that the regulator/alternator should put out a little more voltage than the battery at about 2k rpm and that's a good way to check. I plug the meter in with the bike turned off(battery's been on the trickle charger for a bit), it's sitting at a little over 12v. I start the bike up and check the voltage, 11.85v or so. I rev the motor up, no change, in fact, the voltage is dropping as it idles, 11.84, 11.83 etc. So, I'm pretty sure it's the regulator. Last ditch effort, I check the fuses. I find a bad one, fuse #2(ignition switch 30A). I look around my garage and I find the largest fuse I have laying around, 20A. I throw that one in there, start the bike up, it blows. Not sure what that's all about, I'll run get a few 30A's so I can try one of those. Why would I be blowing the "ignition switch" fuse? BTW, the bike will still start with the blown fuse in there. Any ideas?

DEcosse · 04-26-2008

Fuse 2 is actually the fuse from the regulator to the battery (see schematic below) - so if it's blown then you are not charging the battery.
Put the correct fuse in - if it blows again, you may have a shorted regulator.
Unplug both connections to the regulator:
With your test meter set to 'ohms' check in turn between each of the three yellow wires in the 3-pin connector to both the red & blacks in the 4 pin connector (the two reds are already connected to each other, as are the two blacks). Also check between the reds & the blacks. None of these should readings be 'short' (zero ohms).
Inspect the wiring at the three-pin connector - if the bike's harness looks charred/burned that is a sign the regulator has shorted. There is possibility it could have taken the stator with it.
Incidentally, the cable that plugs into the three pin connector - that should be a replacement auxiliarry harness: the original was deemed too small gauge for the job & was replaced with the auxiliary one as a recall. You should find that cable is stand-alone from the main bike harness and you can follow it back to the stator output connection. At both ends you should find the connectors of the original harness that is 'laced' into the complete harness. If you do not find that auxiliary harness, you need to get it. You should be able to get it at no charge from Triumph if the records on your VIN show it was never supplied.

jscoggin · 04-26-2008

So, I unplug both plugs to the Regulator/Rectifier and I Ohm it out, no shorts. I unplug the primary harness between the R/R and the Stator and I Ohm those wires out, no short. I Ohm everything out to ground and there are no shorts anywhere. I'm feeling good now, I drop in the correct 30A fuse and I check the bat voltage before I start the bike. 12.7v, we're good to go. I start up the bike and the voltage jumps to 13.4v, let it idle for a few minutes and all is well. I rev the bike up to 2-3k and the voltage drops to 13.2v. I had been searching around the forum here earlier and had run across this post Weak charging system? - the solution. So, I run out to wally-world and I grab my self some 12G wire and a 12G 30A in-line fuse. I mod the wires according to the post, including soldering and heat shrink for extra security. I start the bike up and check the volts, 14.4V, I rev the bike up and I still get 14.4v. Success!!! All is well for 10 bucks in parts. Thanks guys for all your help.

Sprocketjockey · 04-27-2008

Same bike, same problem, same fix , same results. All is good and I still owe Zam a drink.

DaytonaNewbie · 04-28-2008

I just got my 02 CE back from the shop after having the same problem. Got an all new harness installed courtesy of Triumph. Main fuse was kind of melted up but didn't POP. Voltages did the same as you described. The shop tech told me the new ones wires are about 3 times larger than the original. Got a first look at it today & I'd have to agree. All seems good now, so far.

DEcosse · 04-29-2008

Quote:

Originally Posted by DaytonaNewbie

...The shop tech told me the new ones wires are about 3 times larger than the original.....

That should have been done about 5 years ago - it was a recall item. Everyone with a 2002 should check to see if the auxiliary harness is installed & if not, get it (should be free of charge under recall)