nklr - important recall notice in wsj 6/5/11

[david]

My 2006 KLR quit charging several months ago. It took a while to find out because at first I thought it was the 4+ year old original battery. (Reader Digest version - It left me stranded with a two mile hike out, then I begged a 17 mile ride back to the house. Bought the only battery I could find in stock which was a cheapo brand. Hiked back in the next day in a rainstorm with tools and new battery, replaced it and climbed out over terrain that was OK for the KLR when dry but a handful when wet and muddy.) I kept the new battery on a battery tender throughout the winter and only did short one hour or less rides. However, on my first three hour tight trail ride at 2000-3000 RPM with the fan running off and on the same thing happened. Luckily this time I was only 100 yards or so from a paved road that had a nice a downhill. I did a bunch of research on this discussion list and found the Electrosport guide plus some good info from someone named Greg. I've run through all the tests three times all with the same results. At 3500 RPM my battery voltage is 12.4v and repeated starts show the voltage continuing to drop. I also replaced the cheapo battery again with one day left on the Cycle Gear 6 month warranty! Two tests in the Electrosport troubleshooting guide consistently fail. One points to a bad stator, the other to a bad rectifier! The stator output/yellow wire to engine case resistance test on section B has 0 ohms which seems to indicate the stator. However, some of the rectifier diode tests on section C also failed. The white output (+)/VOM red to 3 AC inputs (yellow wires)/VOM black test and the black output (-)/VOM black to AC inputs (yellow wires)/VOM red test all had 0 volts. The other other two diode tests, the second and fourth tests on section C passed with all readings around 4.7 volts. Since a rectifier is cheaper and easier I'll try that first. Any last minute advice before I spring for a new one?

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "David" wrote:

> > My 2006 KLR quit charging several months ago. It took a while to find out because at first I thought it was the 4+ year old original battery. (Reader Digest version - It left me stranded with a two mile hike out, then I begged a 17 mile ride back to the house. Bought the only battery I could find in stock which was a cheapo brand. Hiked back in the next day in a rainstorm with tools and new battery, replaced it and climbed out over terrain that was OK for the KLR when dry but a handful when wet and muddy.) > > I kept the new battery on a battery tender throughout the winter and only did short one hour or less rides. However, on my first three hour tight trail ride at 2000-3000 RPM with the fan running off and on the same thing happened. Luckily this time I was only 100 yards or so from a paved road that had a nice a downhill. > > I did a bunch of research on this discussion list and found the Electrosport guide plus some good info from someone named Greg. I've run through all the tests three times all with the same results. At 3500 RPM my battery voltage is 12.4v and repeated starts show the voltage continuing to drop. I also replaced the cheapo battery again with one day left on the Cycle Gear 6 month warranty! > > Two tests in the Electrosport troubleshooting guide consistently fail. One points to a bad stator, the other to a bad rectifier! The stator output/yellow wire to engine case resistance test on section B has 0 ohms which seems to indicate the stator. > > However, some of the rectifier diode tests on section C also failed. The white output (+)/VOM red to 3 AC inputs (yellow wires)/VOM black test and the black output (-)/VOM black to AC inputs (yellow wires)/VOM red test all had 0 volts. The other other two diode tests, the second and fourth tests on section C passed with all readings around 4.7 volts. > > Since a rectifier is cheaper and easier I'll try that first. Any last minute advice before I spring for a new one? >

David, I will be the first to admit, it is electrickery, not electricity. As you have discovered: Your charging voltage is insufficient to keep a battery charged, and at 12.4 v, you are in a discharge state the entire time you bike is running and the light is burning. It requires >12.6 volts charging volt (more like 13.2v+)to keep a battery charged. Q. Are you certain that the battery is properly service to the full line with distilled water and then charged at ~1a? You are consulting the Electosport trouble shooting guide: Q. does that mean you have an Electrosport 'upgrade'? which indeed, many have found to be less than upgrade-ish. What I do know, is that a lot of people that have upgraded for more watts, retro-graded again to their OEM stator for near 100% reliability. I also recall the OEM rectifier was insufficient for the upgraded volts produced in the Electrosport stator. I also seem to recall, that Mr. Fred/Arrowsport quit selling the Electrosport products because of their high failure rate. I will defer to your trouble shooting/test of the rectifier: seems you have found a problem as well. Based on what I have followed from past forum post-- I would suggest you return to OEM stator and see if that cures your reliability problem (after you cure the [allegedly]failed rectifier). revmaaatin.

[mechanizeinc]

If you're running an aftermarket, higher output stator, I have no experience but have heard of two potential issues regarding such upgrades: they tend to fail themselves and they tend to burn up regulator/rectifiers. But I would check your grounds and wiring connectors before spending too much on replacement parts. Mech

[ccimcrb]

Recent recall announcements filed with the National Highway Traffic Safety Administration include reports of flawed motorcycle handlebar assemblies that could cause riders to suddenly lose control. Polaris Industries, a maker of motorcycles, snowmobiles, all-terrain vehicles and other power-sports equipment, is recalling certain Victory Cross Country motorcycles from the 2011 model year because their handlebar clamps or risers may have been machined improperly. As a result the clamps could allow the bars to move or slip unexpectedly. Such sudden movement of the handlebars could lead to a crash. The recall affects 840 bikes built from Jan. 1 through April 11 of this year. Polaris says its dealers will replace defective riser and clamp assemblies free of charge. The recall is expected to begin this month 2011. Owners may contact Victory at 888-704-5290. Off-road motorcycle specialist KTM is recalling certain bikes form the 2010 and 2011 model years because their handlebar clamps may form cracks due to improper heat treatment during the manufacturing process. The problem can lead to the bars loosening and moving around unexpectedly. The recall includes 1,228 KTM 450 EXC, 530 EXC and 690 Enduro R, and Husaberg FE 570 and 570s models built from November 2009 through October 2010. Under the recall, which is to begin this month, KTM dealers will replace the defective clamps free of charge. Customers can contact KTM at 888-985-6090.