ZX6RR 2003 charging problems - again

[MrFaulty]

Hi, hope someone can point me in the right direction. I recently replaced the regulator in my ZX6RR due to it being stuffed (was only pumping out about 11 volts). Now it blew a headlight - but it is not blowing the high beam, so I thought it may be overcharging (a stuffed regulator again I guessed), this morning it was sluggish to start so I took the battery out and put my spare in, the battery in the bike had popped the plugs, like it was overcharging but it seems like it doesn't have enough charge now.

I will take it to an auto elec but getting in at this time of year isn't going to happen. Any suggestions please.

Thanks
Ben

[oldman]

Sounds like you got a bad new voltage regulator. You can easily find out if you have a voltmeter. First take your battery out of the bike and give it a trickle charge, no more than 4 amps max preferably 1.0 to 1.5 amps for about 5 hrs. Make sure you check the battery fluid before charging as if it is dry, charging will destroy your battery. After you have charged the battery put it back in the bike and check the voltage, (it should be above 12 volts, duh). Then load the battery by turning on your key and any lites that will work without starting the motor. DO NOT START THE MOTOR WHEN DOING THIS TEST. Check the voltage again, it should gradually decrease to something above 12 volts, 12.1 or 2.
It should stabilize at this voltage then gradually increase a few 10ths of a volt up to 12.3 or 4. This is the sign of a good battery. If it ever goes below 12 volts it is shot. If all this is ok start the bike, at an idle there will not be any measurable charging voltage but at about 4,000 RPM the charging voltage should be between 14 and 15 volts, never over 15. If it is overcharging there is your problem. Do not run it if it is overcharging it will destroy more than a headlite, (ECU, injectors etc.). A shot of Jim Beam and a pint are good trouble shooting tools.

[MrFaulty]

yeah thanks. Buggered the reg, no more second hand in newcastle, sydney wreckers want almost new price (well half anyway), so I am going to find one with same bolt hole centres and change the wiring, apparently it isn't two difficult

[MrFaulty]

Ended up putting a ZX9 (1998) reg on, it is significantly bigger but just fits so should be better anyway. Kawasaki Newcasle were kind enought o provide the wiring diagrams and a few beers later I had it figured out. Seems to work, at least it is only pumping out 13.5 volts now instead of in excess of 17!! Adamstown Which Bike sold me the reg for $80 - instead of the ridiculous prices quoted by some sydney wreckers (up to $200!!).

Thanks
Ben

[oldman]

Good job. I find any work easier with a few brews. 13.5 volts is ok if you have a fully charged battery. You might want to ride for awhile and recheck the charging voltage as for long term 13.5 is a little low. However unless you have a precision volt meter the voltage may be off. Just look at your headlite when at idle it will be dimmer than at 3500 or 4000 RPM. If it brightens when you raise the RPM it is OK.