After the wiring recall last February I still had my third stator failure so I replaced the stator, rotor, rectifier, and battery on my '02. All was up to spec. Then on a recent ride, couple hours of hot city driving, the voltage suddenly drops from 14.1V to 13.6V and has stayed there. At the low end of normal I start to worry again. The 30 amp fuse wire is also heating up enough to discolor. I checked cleaned and greased the connectors to no avail.
Not wanting to get stranded again I replaced the new recall fuse holder and 2" of wire with an ATO heavy-duty in-line fuse holder with 12 ga wire on it from the auto parts store. Also I noticed comparing the before and after recall wiring diagrams that the rectifier sensor wire now ties in just downstream of the rectifier so it would not compensate for voltage loss at the fuse so I reconnected it at the new fuse holder. This brought up the system voltage at 5000 rpm to 14.3V.
It appears to me that the wiring recall 30 amp fuse holder and R/R monitor wire routing is an improvement but still is weak. Thanks to the information I have received here at VFRD I am able to diagnose and repair my bike and if I missed something here please let me know. Thanks VFRD.
[image: View Post]Bad Boy, on Aug 19 2008, 11:32 PM, said:
Not wanting to get stranded again I replaced the new recall fuse holder and 2" of wire with an ATO heavy-duty in-line fuse holder with 12 ga wire on it from the auto parts store. Also I noticed comparing the before and after recall wiring diagrams that the rectifier sensor wire now ties in just downstream of the rectifier so it would not compensate for voltage loss at the fuse so I reconnected it at the new fuse holder. This brought up the system voltage at 5000 rpm to 14.3V.
Good idea. cassandtim and I were just discussing the same upgrades after he gets his new harness from the dealer next week. :fing02:
I've got an extra 6th gen VFRNess w/ accessory relay and fuse box (unused) I'd sell if you're interested. This was one of the first mods I did after all the problems I had with my 4th gen. Ordered two because a buddy has a 6th gen too, but he sold it before we installed the VFRness.
[image: View Post]klinquist, on Aug 20 2008, 08:11 AM, said:
I've got an extra 6th gen VFRNess w/ accessory relay and fuse box (unused) I'd sell if you're interested. This was one of the first mods I did after all the problems I had with my 4th gen. Ordered two because a buddy has a 6th gen too, but he sold it before we installed the VFRness.
Very kind offer. Our Honda dealer here already has the factory upgrade harness in stock and ready to install, so we'll just beef it up where necessary once they install it. I'm sure someone here wants that VFRness though!
I was afraid of this. This is why I didn't let the stealer beat the he!! out of my bike, at the expense of my bike-less time, just to have new , (or the same old), problems, plague the bike.
Thanks to all of you who did the research, and did the wright-ups, to fix my bike.
Tim (cassandtim) and I significantly upgraded his new recall harness to prevent problems that some guys have already been having. I'm not sure it's true of every new harness, but on Tim's the 12V sense wire was pretty immediately tied into the red/white wires out of the R/R, somewhat avoiding the issue of traversing the front harnesses and a bunch of loads that would vary the voltage.
All we did was splice in 2 10-gauge (overkill, but it was handy at the time) ground wires to the green R/R wires and run them directly to chassis ground on the frame aft of the rear cylinder head, then spliced in two 12V wires to the red R/R wires and ran them into a single heavy duty fuse holder (you could use two; we only had one handy and figured it was enough. If you use three holders, go with a 15A (15 amp) fuse where the 30A fuse is presently, and use a 10A in each of the new fuse holders; you should have no problems with blown fuses) before connecting directly to 12V "+" at the battery. We swapped the 30A main fuse for a 20A and put a 15 amp in the new fuse holder (for a total of 35A potential), and have had no problems. If I remember correctly, voltage now reads a rock solid 14.3-14.4V at all revs/loads, whereas before it was 13.9 at idle and over-charging at mid to high revs.
His red/white 30A wire should never get hot now. It is incredibly damn stupid that Honda feeds the battery via the R/R through that fuse. They even merge the two beefy red wires from the R/R into one, the infamous and still-too-small red/white wire. Make sure and fix Honda's fix. :dry:
End of thread · 6 posts recoveredWayback Machine snapshot 12 Apr 2010