2022-09-01 No Charging to Over Charging!

The R100 RT now starts every time, idles clean, and apparently carbs, lower and top end are fine.

But no charging

It has an aftermarket charging system  and Regulator Rectifier 

After digging through the EME site, found that the Black wire should be +12 VDC, and very close to battery voltage. It's the RR 'sense' wire, so if voltage on that wire is less than true battery voltage, the RR will be 'tricked' into thinking the battery is LOW and output HIGH. As found condition = 0 VDC. NOT SAT.

So, connected a jumper direct from battery to black wire, started bike and *voila* we have output. Lots of output! Too much output! As in at 16 VDC I stopped the test.

Hmm, other things can cause high output, rather than failed RR..

1. Checked battery cable to ground, 0.2 ohms. SAT.
2. Checked for any grounds from any RR lead. All open, as should be. SAT.
3. Installed new ground wire from RR 'case' direct to battery. Nice clean, stranded (not solid wire, as-found <gasp>). 0.05 ohms. SAT.Fired her up, still high charging.

NOTE - Barrie told me, originally, the RR was mounted under the tank and it got very hot, was relocated to side frame rails, zip tied, with a #10 solid wire from RR 'ear' to battery ground.

Got distracted. Noticed Barrie had installed a 'power installation' point (bolt through rear fender, stacked with copper washers) direct from battery. Replaced the wire with bigger gauge, and, more importantly, a 20 amp fuse. In case of big direct short, don't want a battery explosion.

Fired the old gurl up and WOW, 14.1 volts at 4k. DAYUM, got all excited shit.

Noticed the high beam headlight is out. Without that load, battery volts as read by Fluke 87 DMM increased to 14.8, but that's acceptable.

Switched back to low beam, 14.1 for about 20 seconds at ~4k rpm when BAM, right back up to 16 Vdc. Shit.

Called the fine folks at EME, what GREAT peeps they are! Jodi, Mullin, and Matt. 

Discussed the test configuration (batt direct to black) output direct to battery, and they agree the RR is rectifying, not regulating. 

Interesting my CBX does the same thing w/ aftermarket ZX7 alternatort kit. Am I cursed?

Long of short, yesterday ordered new RR along with other parts from EME. Fun to spend Barries' money :). Approx 220 USD.