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Buell Forum » 1125R Superbike Board » Stator/Voltage Regulator/Charging System subforum » Archive through November 02, 2013 » My writeup on fixing the charging system « Previous Next »

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Baf
Posted on Saturday, February 02, 2013 - 12:20 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Answering questions and posting pictures recently has gotten me to finally finish up my full writeup on fixing the 09/10 charging systems. It describes everything I've done with mine, including EBR rotor, stator rewind, and regulator swap. Inspired by Hildstrom's writeup.

Here's it is (first draft, at least; this link will always go to the latest version though): http://projects.baf.cc/pdf/motorcycle/1125charging system.pdf
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Redbat
Posted on Saturday, February 02, 2013 - 12:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Very nice write-up Baf. Thanks for taking the time to document these steps.
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Andros
Posted on Sunday, February 03, 2013 - 10:22 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Classy!!
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Dannybuell
Posted on Sunday, February 03, 2013 - 08:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Wow! that PDF document is so professional!
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Theothers2t
Posted on Monday, February 04, 2013 - 10:03 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Baf;

As an owner of an '09 R that has not had any problems yet, Thank You so much for taking the time to do this! I know it is inevitable that I will have to fix mine someday, and this summary will really help. Thanks!!
Dave
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Hildstrom
Posted on Monday, February 04, 2013 - 01:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Baf, Thanks for taking the time to document your experience. I added a link to your pdf on my page.
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Andros
Posted on Monday, February 04, 2013 - 03:15 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Baf if you feel like writing some more I would love to see a step by step guide on how to wire the plugs onto the ce605. =)
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Baf
Posted on Monday, February 04, 2013 - 05:39 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Wow, thanks for all the compliments!

What do you need to know about wiring the plugs on the CE-605 specifically? The 3 input wires go to the stator plug (order doesn't matter), and the two output plugs go to the wiring harness (red to red, black to black). If there's anything specific you'd like to see elaborated on, let me know.
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Andros
Posted on Tuesday, February 05, 2013 - 01:27 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanx baf! Maybe a pic of the vr with the plugs on?
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Dualbuells
Posted on Sunday, March 03, 2013 - 09:17 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Is there a alternative silicone for the "HD High-Performance Gray sealant #99650-02? I really don't want to purchase any amount of material from HD unless forced to.
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Baf
Posted on Monday, March 04, 2013 - 08:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

@Andros - there are some pics of it installed. I don't have any pics handy of just the regulator.

@Dualbuells - I just used black RTV and it's been fine. I used this stuff: http://www.amazon.com/Permatex-82180-Maximum-Resistance-Silicone/dp/B0002UEN1U

(Message edited by baf on March 04, 2013)
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Cravacor
Posted on Friday, March 22, 2013 - 11:59 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Great write-up Baf. Thank you.
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Thefleshrocket
Posted on Friday, March 22, 2013 - 02:06 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Informative write-up. I've got an '08 so hopefully none of this will ever affect me, but an interesting read nonetheless.
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Mako
Posted on Saturday, March 23, 2013 - 11:05 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

great info, thanks
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Brumbear
Posted on Saturday, March 23, 2013 - 12:22 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

OUTSTANDING Baf Outstanding
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Ezblast
Posted on Sunday, March 31, 2013 - 01:42 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Very good!
EZ
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Websii
Posted on Monday, June 03, 2013 - 02:37 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Have you had any issues with the VR being mounted there? I'm thinking of following your write up but my bike is my commuter, and i'm thinking that area gets quite wet when it rains...
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Baf
Posted on Wednesday, June 05, 2013 - 09:20 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

No issues with VR yet. I wouldn't worry about the rain, the CE-605 is all potted/sealed up.
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Websii
Posted on Wednesday, June 05, 2013 - 02:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thank you sir!
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Froggy
Posted on Wednesday, June 05, 2013 - 02:38 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The VR is designed to be exposed to the elements.
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Jdino
Posted on Wednesday, June 12, 2013 - 05:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Awesome write-up Baf. I am currently in the process of fixing my charging system and this is a lot of help. My only question is in regards to the Deutsch DTP06-4P connector you listed under "materials required" for the CE-605SB Regulator installation. I cant find the Deutsch DTP06-4P connector anywhere. I can only find DTP04-4P or DTP06-4S. Not sure if its a typo in your write-up, or I'm looking in the wrong places. Some guidance for this newbie would be much appreciated.
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Hardcorps
Posted on Saturday, June 15, 2013 - 08:11 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

How did you obtain 295Ft lbs as recomended by EBR with out going out and buying an expensive torque wrench? I stopped at my local mechanics who I am friends with and their torque wrench only went to 195ft lbs?
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Baf
Posted on Saturday, June 15, 2013 - 09:59 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Jdino - oops, sorry about that.It is indeed the DTP04-4P. Make sure you get the stamped pins, not the solid pins, the appropriate deutsch connector crimpers (I got mine on ebay), and one of the sealing plugs since you're only going to use 3 of the 4 positions on the connector. I'll have to update my writeup with all of this info.

Hardcorps - I used an impact wrench that topped out at 300 ft-lbs, so I just torqued it on with that. Some folks would advise against doing that though. Otherwise, you can go low-tech and do some math on it. If you put 295 pounds 1 foot out from the socket on a breaker bar, that's 295 ft-lbs of torque. Just take 295 and divide it by how many pounds you weigh, and stand on the breaker bar that many feet out. : )

(Message edited by BAF on June 15, 2013)
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Sparky
Posted on Saturday, June 15, 2013 - 03:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

One can also get a torque multiplier and do the math to obtain 300 ft-lbs for whatever torque wrench you have, I believe. That process was explained on BWB before - search the archives.
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Andros
Posted on Friday, September 13, 2013 - 07:13 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

YOU*RE A CHAMP! THANK YOU!!!!!
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