2007 GTX 155 No Charge

[Grsanchez86]

Hello all I’ve done some searching but haven’t found an answer so here it goes:

I’m having charging issues with my 07 GTX 155. Checked stator resistance at the rectifier plug, .5,.5,.5 ran the vAC test while ski was running got outputs around 50-60 vAC. I have no continuity from stator to ground. I have decreased battery power to the rectifier but not significant (battery shows around 13.15 v) red cable at rectifier shows 12.8. I have good ground. Both battery and charging 30a fuses are good. The issue is I am not charging at all. I bought an after market rectifier put it in last night, still not charging. Anyone run into this or have any suggestions?

 

[ski-d00]

A very common problem is the 2 small red wires at the solenoid. These corrode in the over molded terminal.

All you have to do is track down the bad connection. It may also be at the fuse panel. With it running, check voltage at regulator. Then check at battery. The problem is usually in between.

 

[Grsanchez86]

If those cables are bad would I still get 12.8v at the ski side of the rectifier plug? To check voltage at the regulator I should hook my red and black leads directly to the regulator plug and see 14+ Volts, correct?

 

[ski-d00]

yes and yes

 

[Grsanchez86]

yes and yes

Hmmm, I did that last night and was only getting 3vDC or so off the regulator. Maybe this after market regulator is bad from the factory. Ok, this gives me a little bit more to dig into at least. I’ll check and report back. Thank you!

 

[Grsanchez86]

So after inspection the wires seem to be molded into the fuse box. Is this fuse box repairable or do I have to replace it? Also, can I run new wires directly off the battery to the fuse box or do they have to jump from the solenoid?

 

[ski-d00]

Checked stator resistance at the rectifier plug, .5,.5,.5 ran the vAC test while ski was running got outputs around 50-60 vAC

This is too high, should only be around 25v. You are checking the yellow to yellow on all 3 wires for AC voltage?

 

[Grsanchez86]

This is too high, should only be around 25v. You are checking the yellow to yellow on all 3 wires for AC voltage?

Yes, yellow to yellow with my black and red leads off the ski side stator plug near the regulator. I’ll check them again to get exact readings. 3500 RPMs correct?

 

[ski-d00]

So after inspection the wires seem to be molded into the fuse box.

They are not molded into the fuse box. You are seeing the silicone seal on the bottom side. Terminals can be removed by depressing the tang on the terminal.

 

[ski-d00]

3500 RPMs correct?

Yes, but even at idle speed you will have decent voltage.

 

[Grsanchez86]

They are not molded into the fuse box. You are seeing the silicone seal on the bottom side. Terminals can be removed by depressing the tang on the terminal.View attachment 60314

So just run new wires off the starter solenoid to these?

 

[ski-d00]

Yes, if the red wire to the 30 amp charging fuse is bad. Just do a continuity check from the fuse panel with the fuse out to the solenoid.

 

[Grsanchez86]

Checked the stator while running. 21-23 vAC at idle, 50ish vAC at speed. Checked the two fuses at the fuse box that have the red wires off the main battery cable, the Battery fuse labeled battery had 13.15v, the one labeled charging had 12.89v. Is that a resistance wire? Everything is pointing to the rectifier but I replaced it and still got no charging. Any other place to look?

 

[DualSportDad]

Did you check both sides of the fuse? Mine was burned up. Also cut the connector off the stator and the ski side of the harness and solder them together, those always burn up. On mine I updated the rectifier to the 08+ rectifier. Buy a fh020aa rectifier from a Ducati on eBay and then find a quality connector kit and wire it in. This mosfet rectifier holds steady voltage. Here is a picture of my setup, I ran all new wires to the stator and battery by passing the fuse box all together. Positive charging wire is fused at the battery. Make sure you use at least 14 gauge wire for everything.

 

[Grsanchez86]

I figured it out, the small wire that is molded into the battery cable was showing voltage 12.8 (battery was at 13.15). But as soon as any load or voltage was put on, it dropped to about 6v. I replaced the wire with a new 12guage wire and shes charging great! Thank you everyone for your help.