ZX6RR 2003 Voltage Leak

[MrFaulty]

Gday, hope someone can offer some advice

I replaced my Regulator/rectifier (after market) a few months back and now it appears as though I have a leak in my electric system, at first I thought it was a stuffed battery not holding charge but I checked it by charging the battery, checking the voltage (12.46) then checking it again 9 hours later (12.46); I then connected the battery and drove to work, checked it (12.46), then just checked it again 3.5 hrs later (12.26).

I am at the stage where I think I need to take it to a bike mechanic (probably B&C at Boolaroo) but I am worried as they have told me they don't know how long it will take to locate the "leak", hence I am not sure what $ I will be up for - if I could locate the leak and just get them to fix it it would be better.

Thanks
Ben

[tim]

so have u replaced your battery recently? When was it last replaced? How often have you been riding over winter?

Anyone have experience testing sitting current drain from the battery and comparing it to 'normal' drain is an effective way to test if it's an internally failing battery or an electrical gremlin?

Man, you chose the right name when you signed up here!

[MrFaulty]

LMAO yeah, just found another thread, definitely a leak - I disconnected the negative terminal and hooked the multi metre up between the neg cable and the neg terminal, looks to be a leak of approx 35mA.

I ride the bike everyday and the battery was replaced in February or March (can't remember as I cleverly threw out the receipt!).

It's a great bike apart from the electrical system!!

[tim]

ok next step is to get the service manual with wiring diagram and locate fuses wiring looms and devices etc that draw current and are connected always not on ignition. Assuming it's not an ignition barrel problem, with the ammeter connected pull out devices/fuses/wiring plugs etc until you see the current draw drop.

If you start closest to the battery in the circuit not physically it will help you quickly work out which part of the loom to focus on in order to narrow your search.

[MrFaulty]

okay, thanks - sounds like it will keep me busy over the weekend!

[MrFaulty]

Problem solved! Identify/confirm site of voltage leak by cutting rectifier wires, reconnect with a plug to make the job easier next time, then take the blasted thing to a motorbike mechanic!

[tim]

Well done! How much current was it drawing?

[MrFaulty]

It was drawing 35mA

Only one small prob, on the way home yesterday I almost ran out of fuel due to the fuel indication light not working! so then it started to get a bit dark and noticed the headlights don't work, so hit high beam, no high beam or high beam instrument panel light!

Got home and took the fuel tank off and the only obvious thing I can see is that the black with yellow stripe ground wire going into the rectifier plug has been cut and left hanging - bear in mind it is an after market rectifier. Checked the headlights, they aren't blown.

Spoke to the mechanic this morning, he cant look at it till Monday but suggested I ground that wire and see what happens!

Not overly happy

[tim]

change your forum name mate something like "MrReliable"

[tim]

auto electrician instead of bike mechanic?

[MrFaulty]

Most auto elecs wont touch a bike to my knowledge - everyone told me I have to see a motorbike mechanic; and after forking out the dollars already I expect him to fix the problem. If I have to spend any more money I will source a genuine rectifier from o/s (not waiting 6 weeks for Kawasaki to get me one) and put it in as per the wiring diagram.

A real PITA

[MrFaulty]

and the saga continues!!!!

Found and fixed the problem last night - the mechanic in question has neglected to connect one of the positives coming out of the wiring loom (the yellow one). So I fixed it and in fixing it I noticed it has a different battery than it went in with and this one looks significantly older! I can't resolve the issue till next Monday as the mechanic who did the work is off till then but it will be very interesting to see what they say. Also they drilled into the frame for an earth when there was no need to as there was a perfectly good earth wire there!

Not happy Jan!!

[Phantom]

and the saga continues!!!!

Found and fixed the problem last night - the mechanic in question has neglected to connect one of the positives coming out of the wiring loom (the yellow one). So I fixed it and in fixing it I noticed it has a different battery than it went in with and this one looks significantly older! I can't resolve the issue till next Monday as the mechanic who did the work is off till then but it will be very interesting to see what they say. Also they drilled into the frame for an earth when there was no need to as there was a perfectly good earth wire there!

Not happy Jan!!

"Not happy Jan".... you have got to be kidding; if some R sole bar stard drilled my frame they would be buying a new frame and paying for the dissasembly/reassembly.

From what you have written it sounds like they swapped batteries on the sly too. I can smell fish big time.

[MrFaulty]

Yeah, I spoke to the mechanic in question yetserday and he wasn't overly helpful and simply told me there was no way he swapped batteries and he says he charged it in the bike so it didn't even come out - I suggested (to give him an easy out) that maybe his offsider swapped it for some reason and forgot to bput the original back it but he said no way.

I then asked him when I could bring it back to fix the wiring and he asked what needs fixing so I told him I wanted it lookign right as I fixed it by going direct to the battery. He reckons he cant do it for a few weeks on a Saturday and I can't really be without it during the week. I think I will probably have to fix it myself but will call him on Saturday again to discuss and maybe mention the hole he drilled in the frame.

I think it will be a case of cut my losses and I won't buy anything from him let alone get any work done - and of course if any one asks my opinion I wouldn't dream of putting sh!t on the guy!!

and the saga continues!!!!

Found and fixed the problem last night - the mechanic in question has neglected to connect one of the positives coming out of the wiring loom (the yellow one). So I fixed it and in fixing it I noticed it has a different battery than it went in with and this one looks significantly older! I can't resolve the issue till next Monday as the mechanic who did the work is off till then but it will be very interesting to see what they say. Also they drilled into the frame for an earth when there was no need to as there was a perfectly good earth wire there!

Not happy Jan!!

"Not happy Jan".... you have got to be kidding; if some R sole bar stard drilled my frame they would be buying a new frame and paying for the dissasembly/reassembly.

From what you have written it sounds like they swapped batteries on the sly too. I can smell fish big time.