Changed Regulator but still over charging

[FJ66Cager]

My FJ was burning up batteries once a year.   I had replaced the alternator with a factory new one about 7 years ago but it didn't seem to last long.   I recently replaced the regulator with the Nippon Denso internal regulator but it still seems to be over charging the battery.   The battery is toast so i'm wondering if the overcharge now is because the battery is so cooked (yes, I did fill it up with distilled water)   Or did I miss something in installing the new regulator.

Any ideas?   Anyone??   Beuller??   Beuller?

[SlowOldGuy]

Check that the wire supplying "battery" voltage to the alternator is reading a full 12 volts (or whatever the actual battery is reading).  This is usually the red wire in a red(ish) 2 connector plug with a brown(ish) wire under the left sidecover.

If it's not showing full battery voltage, then the alternator will overcharge the battery.

On my '85, this connector was partially melted and I had to replace it with signal blade connectors to get the battery and alternator to properly communicate voltages.

DavidR.

[fj316]

I found that my newly replaced battery was bloated and had to purchase a new one. I found this thread and got a Electrex RG25 regulator in case mine was busted and needed changing. I noticed my connector from the regulator had partially melted like SlowOldGuy mentioned. So I cleaned the connector inside the regulator and I'm going to replace the blade connector ASAP.

But what puzzled me was that it seems to deliver the voltage it's supposed to. At idle it was battery voltage and when revved to 5k and peaked to 8-9k it showed 13.5V. As the battery is brand new and reads 12.5 to 12.7 volts it looks to me that things are in order as far as i can tell.

There was a small crumpled metal lump the size of a large pinhead that fell out when i removed the alternator cover. I looked around for internal damage or the source of origin but it looked fine inside and gave what I consider to be ok readings on the voltage so I don't know if that is something to worry about in the future. It might have been the cause of a short that made the battery bloat but that is just my speculation.

As the regulator was pretty expensive I'll be returning it today since there is a lot of other repairs needed on the bike before I replace seemingly working parts but I posted here just to give my experience and in case I have made a mistake somewhere in my tinkering.

A final question is if there is any difference in the quality of the Electrex compared to the Electrosport one as the Electrex is all that is available locally and should it come to the part needing replacement I want as much bang as I can get for my buck.

[racerrad8]

A final question is if there is any difference in the quality of the Electrex compared to the Electrosport one as the Electrex is all that is available locally and should it come to the part needing replacement I want as much bang as I can get for my buck.

Well, I went to the Electrex world website to check out the regulator and they do not list it on their website that I can find. I did find one listed on another website and the picture looks very similar to the RaceTech or E/S regulator.

You will have to hear from someone that has used that brand to determine the quality of the item.

Randy - RPM

[Pat Conlon]

Setting aside burned connectors and a bad field wire for a moment, my theory on the regulator failure issue is that the internal regulators (both oem and aftermarket) don't like the engine heat and vibration.

I have no other explanation as to why a regulator would test fine in my garage, but then on the road with a heat soaked engine, after a 2-3  hour ride, zing the output to 15+ volts.

The remote mounted Transpo (adjustable) regulator solved the problem. Plus I can dial down the charging output to a AGM friendly 14.2 volts.

Just my theory mind you....

[movenon]

Setting aside burned connectors and a bad field wire for a moment, my theory on the regulator failure issue is that the internal regulators (both oem and aftermarket) don't like the engine heat and vibration.

I have no other explanation as to why a regulator would test fine in my garage, but then on the road with a heat soaked engine, after a 2-3  hour ride, zing the output to 15+ volts.

The remote mounted Transpo (adjustable) regulator solved the problem. Plus I can dial down the charging output to a AGM friendly 14.2 volts.

Just my theory mind you....

Pat, that's the route I am thinking about going also. I like the adjustability. I have an AGM battery also.

Which leads me to ask whats more important to have on an instrument panel, a clock or a voltmeter? I am still waiting for FJmonkey's soda/beer holder.....
In the mean time I ordered a digital volt meter off Flea bay. They are inexpensive and I think a worth while add on so I will know the condition of the battery and  charging system.

George

[delarbreavous]

Pat can you please give us more info on how you solved your overcharging problem, regulator used, wiring etc etc etc. unless there is a topic on this somewhere on the site.

Thanks
Alain

[Pat Conlon]

George, I'm retired so I don't need a clock. 
A voltmeter is handy even with a proper functioning regulator. If something happens and your battery starts discharging, you should know about it. This will allow you to pull your headlight fuse which will extend your riding range before the battery goes flat.

Alain, yes the Transpo mod is in the files section.

Cheers

[movenon]

George, I'm retired so I don't need a clock. 
A voltmeter is handy even with a proper functioning regulator. If something happens and your battery starts discharging, you should know about it. This will allow you to pull your headlight fuse which will extend your riding range before the battery goes flat.

Alain, yes the Transpo mod is in the files section.

Cheers

I relate to the retierment deal.. Just sitting here waiting for package from RPM (clutch mod stuff) and one small box from China (voltmeter) I would bet that the RPM package will be here this afternoon. Got to figure out what to pack along for the WCR... It's been 15 years since I have been on a motorcycle camping road trip.
George

[Pat Conlon]

It will be great to meet you George!

[fj316]

This is why this forum is so friggin' awesome! 

I've taken your theory to heart Pat and sourced locally an equivalent of the Transpo that will be available in 5 days and much appreciate your documentation of the mod.

A voltmeter will also be installed on the bike as the first next thing I do to be able keep an eye out for irregularities. Got a led one from china on the way but will probably look for a local cheap alternative today so that I don't blow out another battery before I can upgrade the regulator.

Thanks again for invaluable information and good luck on your camping road trip guys.