Intermittent Battery Light

Joined Apr 2019
25 Posts | 0+
Oregon
Recently the battery light on my 1993 900 Superlight has been coming on intermittently while riding. It will stay on for maybe 15 minutes; then go off & not come on again for an hour. Admittedly, diagnosing electrical issues is not my strong suit.

So I proceeded to cleaning the battery terminals & all connectors to the terminals, I checked/cleaned the battery ground. Next I traced the various wires from the alternator & the regulator/rectifier & cleaned all of the connectors. At this point there was no obvious problems.

So I verified the battery voltage after a few hours off of the charger. Good. Next I noted the voltage at the battery at idle, as well as at 3,000 rpms (& above). Voltage increased from about 13.5V to 15.5V. This suggests that the alternator is doing it's job. (However, I might mention that during this test the battery ..... light was not on).

Finally, I decided to see if any of my work resolved the issue of the battery ..... light intermittently turning on while riding. After 3 miles into the ride, the light came on & remained on for 15 miles. Then it switched off for the next 35 miles. When I got home (the light was still off), I checked the voltage at the battery which was 13.25V.

So, I am perplexed. Is there an intermittent problem somewhere in the alternator or the regulator/rectifier? A bad connection or short to ground? A faulty battery ..... light? Any ideas would be appreciated. Oh, the only thing I forgot to check was duc96cr's suggestion to check the wire from the positive terminal of the battery & the solenoid. I'll do that tomorrow. Thank you!!!!
 
15.5v is pushing the boundaries a fair bit for the high end limits.
Normal max should be in the mid 14v for most bikes.
 
15.5v is pushing the boundaries a fair bit for the high end limits.
Normal max should be in the mid 14v for most bikes.

Does that suggest a faulty regulator? And if so, would the excessive voltage to the battery cause the battery ..... light to come on?
 
Well, it appears that I have stumbled on the cause of the intermittent battery light issue. By rechecking the voltage output at the battery, the output was as follows: 12.5V @ 1,100 rpms, 15.8V @ 3,000 rpms & 16.0V @ 4,000 rpms. These seems to be way excessive. And, finally, when I removed the headlight for easier access to the regulator/rectifier wiring, I discovered that the plastic electrical connector to the headlight was partially melted. So, unless I have missed another contributing factor, the problem appears to be a faulty regulator/rectifier. Does this sound correct?
 
It looks that way.
Perhaps a better place to ask the question before you start spending would be
a classic bike forum. There will be a lot more experience of this sort of thing there
compared to what is essentially a modern sports bike site.
 
990Glen: Good point. Thank you for the suggestion.

Thinking ahead...since my regulator/rectifier will likely need to be replaced, I would appreciate any recommendations on a new unit. It seems like there are 2 aftermarket options: the Electrex RR51 or the ElectroSport ESR510s or the ESR515. Thank you for your help.
 
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