CX500 GL500 650 Global

hi yes thx for the advice I do have a manual it is just a really tough one to get to thx again for the advice

I'm coming to the party late I know. Five batteries in 12 months? Can you be sure you are not just running the batteries down to dead because of no charging? They may be good batteries that are just not being charged. After finding low dc voltage across the batteries at 3000 rpm, I would stop the engine and disconnect the yellow wire 3 conductor plug (on a GL find this in the plastic bulkhead just rear of the battery). Inspect for melting or burning, that alone can cause charging failure. If they look okay, start the engine (with the yellow wire plug still disconnected) and test all three possible connections of the engine side of the plug (2 yellow wires each test, three times will test all possible combinations) looking for a AC voltage of, oh, 50 to 70 volts AC. If it is appreciably lower than this, the stator is likely to be the problem, and this is common enough after 40k miles, although some last much longer. I don't know the mileage on your bike, and anyway, mileage is only a vague indicator. If the plug is melted, an acceptable and effective fix is to solder the three yellow wire connections together without the plug. There will be three connections to solder and insulate, each will include one yellow wire from the engine, and one from the rectifier. Doesn't matter which way you pair them up as each yellow wire from the engine is connected to a single yellow wire from the rectifier. That's why they are not color coded uniquely. It's 3-phase AC at that point in the circuit.

Another possibility is that there is a short in the bike somewhere, test by lifting the negative lead from the battery with the key off, touch several times to the negative terminal, looking for a spark, if none, probably no short with the key off.

RichNCt wrote:I'm coming to the party late I know. Five batteries in 12 months? Can you be sure you are not just running the batteries down to dead because of no charging? They may be good batteries that are just not being charged. After finding low dc voltage across the batteries at 3000 rpm, I would stop the engine and disconnect the yellow wire 3 conductor plug (on a GL find this in the plastic bulkhead just rear of the battery). Inspect for melting or burning, that alone can cause charging failure. If they look okay, start the engine (with the yellow wire plug still disconnected) and test all three possible connections of the engine side of the plug (2 yellow wires each test, three times will test all possible combinations) looking for a AC voltage of, oh, 50 to 70 volts AC. If it is appreciably lower than this, the stator is likely to be the problem, and this is common enough after 40k miles, although some last much longer. I don't know the mileage on your bike, and anyway, mileage is only a vague indicator. If the plug is melted, an acceptable and effective fix is to solder the three yellow wire connections together without the plug. There will be three connections to solder and insulate, each will include one yellow wire from the engine, and one from the rectifier. Doesn't matter which way you pair them up as each yellow wire from the engine is connected to a single yellow wire from the rectifier. That's why they are not color coded uniquely. It's 3-phase AC at that point in the circuit.

Another possibility is that there is a short in the bike somewhere, test by lifting the negative lead from the battery with the key off, touch several times to the negative terminal, looking for a spark, if none, probably no short with the key off.

Thank you for the replies it looks like the second hand rectifier did the trick and disconnected the autocom also has made life better now its on the switch circuit. all is well and battery is doing great

Good news.Glad you found a fix

For future reference I suspect these Universal 3 phase rectifiers will work on our bikes,

http://www.feked.com/12v-regulator-rect ... state.html

Don't be fooled by the picture as it's in gray-scale but they have 3 yellow and black and red wires.I fitted one to a pal's Triumph Bonneville T140v.It was a single phase but the above is 3 phase would work.They have more than enough current handling for our bikes.